bmw by joel unger

B mw

3 Series

M3, 3181, 3231, 3251, 3281 Sedan, Coupe and Convertible 1992, 1993, 1994, 1995, 1996,1997, 1998

Bentley, Publishers Cambridge, Massachusetts

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

-1 B

ROBERT BENTLEY, INC.

AUTOMOTIVE PUBLISHERS

Information that makes 1734 Massachusetts Avenue Cambridge,MA the differenceo 02138 USA 800-423-45951617-547-4170 www.rb.com e-mail : sales@rb.com

Technical Contact Information We value your feedback . Technical comments and suggestions are helpful to us. Please send your comments and thoughtsto Bentley Publishers e-mail : tech .bmw@rb .com 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/updates

WARNING-Important Safety Notice Do not use this manual unless you arefamiliarwith basic automotive repair procedures and safe workshop practices. This manual illustrates the workshop procedures required for most service work. It is not a substitutefor fui¡ and up-to-date information from the vehicie manufacturer orfor propertraining as an automotive technician. Note that it is not possible for us to anticipate al¡ of theways orconditions 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 orcompleteness ofthe 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 DISCLAIMTHEIMPLIEDWARRANTIES 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 ANY USE OF THE EXAMPLES, INSTRUCTIONS OR OTHER INFORMATION IN THIS BOOK.I N NO EVENT SHALL OUR LIABILITYWHETHER INTORT, CONTRACT OR OTHERWISE EXCEEDTHE COST OFTHIS MANUAL.

Your common sense and goodjudgment arecrucial 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 orcontribute 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 recommendedfor 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. cm. 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 SciencesPermanence 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

Foreword.. ....... .. .. .. .. .. .. .. ....... .. .... .. .. .. .. .... ......... .. .. .. .. .. .. ....... .. .... .. ..... . . . . .. . . .. .. ....... .. . v

Warnings and Cautions . .. ..... . . ...... .. .. .. .... ......... .. .... .. .. .. ....... . . .... .. ......... .. .. .. .. .........vii Index .. .. .. .. .. .. ....... .. .... .. .. .. .. .... ......... .. .. .... ......... .. .. .... . . .... ...... . .... .. .. ....... back of book

General Data and Maintenance Engine

4 6

010 FundamentalsfortheDo-lt-YourselfOwner 020 Maintenance Program

100 110 113 116 117 119

Engine-General Engine Removal and Installation Cylinder Head Removal and Installation Cylinder Head and Valvetrain Camshaft Timing Chain Lubrication System

120 121 130 160 170 180

Ignition System Battery, Starter, Alternator Fue¡ Injection Fuel Tank and Fuel Pump Radiator and Cooling System Exhaust System

Transmission

200 Transmission-General 210 Clutch 230 Manual Transmission

240 Automatic Transmission 250 Gearshift Linkage 260 Driveshaft

Suspension, Steering and Brakes

300 Suspension, Steering and Brakes-General 310 Front Suspension 320 Steering and Wheel Alignment

330 331 340

Body

400 Body-General 410 Fenders, Engine Hood

411 Doors 412 Trunk Lid

Bo y Equipment

510 512 513 515

Exterior Trim, Bumpers DoorWTdws InteriorTrim Central Locking and Anti-Theft

520 540 541

Electrical S stem

600 610 611 612

Electrical System-General Electrical Component Locations Wipers and Washers Switches and Electrical Accessories

620 Instruments 630 Exterior Lighting 640 Heating and Air Conditioning 650 Radio

Equipment and Accessories

720 721

SeatBelts Airbag System (SRS)

Electrical Wiring Diagrams

Rear Suspension Final Drive Brakes

Seats nrt Convertible Top

Automotive Books From Robert Bentley 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 BMW Z3 Service Manual : 1996-1998 4-cylinder and 6-cylinder models Robert Bentley ISBN 0-8376-0327-7

BMW 3-Series Service Manual: 1984-1990 3181, 325, 325e(es), 325i(is), and 325i Convertible Robert Bentley ISBN 0-8376-0325-0

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 Unbeatable BMW: Eighty Years of Engineering and Motorsport Success Jeremy Walton ISBN 0-8376-0206-8

BMW 6 Series Enthusiast's CompanionTM Jeremy .11 ISBN 0-8376-0149-5 W

BMWEnthusiast's CompanionTM BMW Car Club of America ISBN 0-8376-0321-8 BMW Notecards Series 1 Photography by Klaus Schnitzer ISBN 0-8376-0211-4 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 Car and Competition Driving Paul Frére with foreword by Phil Hill ISBN 0-8376-0202-5

The Design and Tuning of Competition Engines PhilipH. Smith, 6th edition revised by David N. Wenner ISBN 0-8376-0140-1 Going Faster: The Skip Barber Racing School Carl Lopez ISBN 0-8376-0227-0 9M-f, Ir- Win non Alexander with foreword by Mark Martín ISBN 0-8376-0070-7 The Technique of Motor Racing Piero Taruffi with foreword by Juan Manuel Fangio ISBN 0-8376-0228-9 Race Car Aerodynamics Joseph Katz ISBN 0-8376-0142-8

The Scientific Design of Exhaust and Intake Systems Philip H. Smith andJohn C. Morrison ISBN 0-8376-0309-9 Volkswagen Model Documentation Joachim Kuch ISBN 0-8376-0078-2 Volkswagen Beetle: Portrait of a Legend Edwin Baaske ISBN 0-8376-0162-2 Glory Days : When Horsepower and Passion Ruled Detroit Jim Wangers ISBN 0-8376-0208-4 Alfa Romeo Owner's BibleTM Pat Braden with foreword by Don Black ISBN 0-8376-0707-9

Ford F-Series Pickup Owner's BibleTM Moses Ludel ISBN 0-8376-0152-5 Harley-Davidson Evolution VTwin Owner's BibleTM Moses Ludel ISBN 0-8376-0146-0

Jeep Owner's BibleTM Moses Ludel ISBN 0-8376-0154-1 Toyota Truck & Land Cruiser Owner's BibleTM Moses Ludel ISBN 0-8376-0159-2 The Racing Driver DenisJenkinson ISBN 0-8376-0201-7 FUEL INJECTION

Ford Fuel Injection and Electronic Engine Control: 1788-1993 Charles O. Probst, SAE ISBN 0-8376-0301-3 Ford Fuel Injection and Electronic Engine Control: 1980-1987 Charles O. Probst, SAE ISBN 0-8376-0302-1 Bosch Fuel In1ection and Engne i Management Charles O. Probst, SAE ISBN 0-8376-0300-5 VOLKSWAGEN OFFICIAL SERVICE MANUUAS

New Beetle Service Manual: 1998-1999 Robert Bentley ISBN 0-8376-0385-4 Jetta, Golf, GTI, Cabrio Service Manual: 1993-early 1999, including VR6 and TDI Robert Bentley ISBN 0-8376-0366-8 Eurovan Official Factory Repair Manual : 1992-1999 Volkswagen of America ISBN 0-8376-0335-8 Volkswagen Inspection/Maintenance (I/M) Emission Test Handbook:1980-1997 Volkswagen of America ISBN 0-8376-0394-3 Passat Official Factory Repair Manual : 1995-1997 Volkswagen ofAmerica ISBN 0-8376-0380-3 GTI, Golf, and Jetta Service Manual: 19851992 Gasoline, Diesel, and Turbo Diesel, including 16V Robert Bentley ISBN 0-8376-0342-0 Corrado Official Factory Repair Manual: 1990-1994 Volkswagen United States ISBN 0-8376-0387-0 Passat Service Manual : 1990-1993, includingWagon Volkswagen United States ISBN 0-8376-0378-1 Cabriolet and Scirocco Service Manual : 1985-1993, including 16V Robert Bentley ISBN 0-8376-0362-5

Volkswagen Fox Service Manual: 19871993, including GL, GL Sport and Wagon Robert Bentley ISBN 0-8376-0363-3 Rabbit, Scirocco, Jetta Service Manual : 1980-1984 Gasoline Models, including Pickup Truck, Convertible, and GTIRobert Bentley ISBN 0-8376-0183-5 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 AUDI SERVICE MANUUAS Audi 100, A6 Official Factory Repair Manual: 1992-1997, including S4, S6, quattro and Wagon models . Audi of America. ISBN 0-8376-0374-9 Audi 80, 90, Coupe Quattro Official Factory Repair Manual: 1988-1992 including 80 Quattro, 90 Quattro and 20-valve models Audi of America ISBN 0-8376-0367-6

Audi 100, 200 Official Factory Repair Manua1 :1988-1991 Audi of America ISBN 0-8376-0372-2 Audi 50005,ctory 5000CS Official Fa Repair Manual : 1984-1988 Gasoline, Turbo, and Turbo Diesel, includingWagon and Quattro Audi of America ISBN 0-83760370-6 Audi 5000, 50005 Official Factory Repair Manual : 1977-1983 Gasoline and Turbo Gasoline, Diesel and Turbo Diesel Audi of America ISBN 0-8376-0352-8 Audi 40005, 4000CS, and Coupe GT Official Factory Repair Manual : 1984-1987 including Quattro and Quattro Turbo Audi of America ISBN 0-8376-0373-0 SAAB OFFICIAL SERVICE MANUUAS Saab 90016 Valve Official Service Manual: 19851993 -ey--Robert Bentl ISBN 0837603129 Saab 900 8 Valve Official Service Manual: 1981-1988 Robert BentleyISBN 0-8376-0310-2 VOLVO SERVICE MANUAL Volve240 Service Manual : 1983-1993 Robert Bentley ISBN 0-8376-0285-8

Robert Bentley has published service manuals and automobile books since 1950 . Please write Robert Bentley, Inc., Publishers, at 1734 Massachusetts Avenue, Cambridge, MA 02138, visit ourweb síte at http ://www.rb .com, or call 1-800-423-4595 fora free copy of our complete catalog, including titles and service manuals for Jaguar, Triumph, Austin-Healey, MG, and other cars .

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 covered by this manual as the E36 model. The code "E36" is BMW's internal code for the basic platform 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 discuss 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 understanding with practical descriptions, step-by-step procedures, and accurate specifications. The BMWowner 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¡ alternatives.

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, consultyour authorized BMW dealer . You may find that he can make the repair either free or at minimum cost . Regardless of its age and whetheror 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 techniques, 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

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

Please read these warnings and cautions before proceeding with maintenance and repair work . WARNING" See also Cautions on page viü " 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 . " Do not re-use any fasteners that are worn or deformed in normal use . 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 . Always replace these fasteners with new parts. " Never 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 . Never work under a car that is supported solely by a jack. Never 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 (ground strap) to prevent others from starting the car while you are under it. " Never run the engine unless the work area is well ventilated . Carbon monoxide kills . " Finger rings, bracelets and other jewelry should be removed 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 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 " Disconnect the battery negative (-) terminal (Ground strap) 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 or shorts 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 will ignite gas trapped in the cells and cause the battery to explode . " Connect and disconnect battery cables, jumper cables or a battery charger only with the ignition switched off, to prevent sparks. Do not disconnect the battery while the engine is running . " 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 . " 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 . " The air-conditioning system is filled with chemical refrigerant, which is hazardous . The A/C system should be serviced only by trained technicians using approved refrigerant recovery/recycling equipment, trained in related safety precautions, and familiar with regulations governing the discharging and disposal of automotive chemical refrigerants. " Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase 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 inflator. 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 (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 or deadly vapors and are highly flammable . Use only in a well ventilated area . Do not use on hot surfaces (engines, brakes, etc .) . " Do not remove coolant reservoir or radiator cap with the engine hot . Danger of bums and engine damage . 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¡ " If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we suggest you leave such repairs to an authorized BMW dealer or other qualified shop. " BMW is constantly improving its cars and sometimes these changes, both in parts and specifications, are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always check with your authorized BMW dealer parts department for the latest information . " Before starting a job, make certain that you have all the necessary tools and parts on hand . Read al¡ the instructions thoroughly, do not attempt shortcuts . Use tools appropriate to the work and use only replacement parts meeting BMW specifications . Makeshift tools, parts and procedures will not make good repairs . " Use pneumatic and electric tools only to loosen threaded parts and fasteners . Never use these tools to tighten fasteners, especially on light alloy parts. Always 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 in accordance with Federal, State and Local laws.

e If battery power is lost or the battery has been disconnected, the power windows must be re-initialized . Both one touch up/down and pinch-protection will be inactive until windows are re-initialized . See 512 Door Windows .

" 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 .

" Before doing any electrical welding on cars equipped with ABS, disconnect the battery negative (-) terminal (ground strap) and the ABS control unit connector. " On cars equipped with anti-theft radios, make sure you know the correct radio activation code before disconnecting the battery or removing the radio. lf the wrong code is entered into the radio when power is restored, that radio may lock up and be rendered inoperable, even if the correct code is then entered . " Always make sure ignition is 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 diagnostíc equipment, check for fault codes prior to disconnecting the battery cables. If the Check Engine light is illuminated, see 100 Engine-General for On-Board Diagnostics (OBD) fault code information . lf any other system faults have been detected (indicated by an ílluminated warning light), see an authorized BMW dealer. " If a normal or rapid charger is used to charge battery, the battery must be disconnected and removed from the vehicle in order to avoid damaging paint and upholstery " 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 .

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

010-1

010 Fundamentals for the Do-lt-Yourself Owner GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . .010-1 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-8 HOW TO USE THIS MANUAL . . . . . . . . . . .010-2 Warnings, Cautions and Notes . . . . . . . . . . . .010-2

GETTING STARTED . . . . . . . . . . . . . . . . . . . .010-2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010-2 Lífting the Car . . . . . . . . . . . . . . . . . . . . . . . . . . 010-3 Raising car safely . . . . . . . . . . . . . . . . . . . . . . 010-3 Working under car safely . . . . . . . . . . . . . . . . . . . 010-4 ADVICE FOR THE BEGINNER . . . . . . . . . .010-4 Planning Ahead . . . . . . . . . . . . . . . . . . . . . . . . 010-4 Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-4 Non-reusable Fasteners . . . . . . . . . . . . . . . . . . 010-5 Tightening Fasteners . . . . . . . . . . . . . . . . . . . .010-5 Gaskets and Seals . . . . . . . . . . . . . . . . . . . . . . 010-5 Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . 010-6 Wire Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . 010-6 BUYING PARTS . . . . . . . . . . . . . . . . . . . . . . . 010-6 Genuine BMW Parts . . . . . . . . . . . . . . . . . . . . 010-6 Non-returnable Parts . . . . . . . . . . . . . . . . . . . . 010-7 Information You Need to Know . . . . . . . . . . . . 010-7

Basic Tool Requirements . . . . . . . . . . . . . . . . 010-8 Jack Stands . . . . . . . . . . . . . . . . . . . . . . . . . 010-9 Oil Change Equipment . . . . . . . . . . . . . . . . . . 010-9 Torque Wrench . . . . . . . . . . . . . . . . . . . . . . . 010-10 Feeler Gauges . . . . . . . . . . . . . . . . . . . . . . . 010-10 Digital Multimeter . . . . . . . . . . . . . . . . . . . . . 010-10 gMW Special Tools . . . . . . . . . . . . . . . . . . . . 010-11

EMERGENCIES . . . . . . . . . . . . . . . . . . . . . . 010-11 Changing a Tire . . . . . . . . . . . . . . . . . . . . . .010-11 Car Will Not Start . . . . . . . . . . . . . . . . . . . . .010-11 Jump Starting Car . . . . . . . . . . . . . . . . . . . . . 010-12 Overheating . . . . . . . . . . . . . . . . . . . . . . . . . 010-12 Low Oil Pressure . . . . . . .. . . . . . . . . . . . . . . . 010-13 Brake Fluid Level . . . . . . . . . . . . . . . . . . . . . 010-13 Check Engine Warning Light . . . . . . . . . . . . 010-13 pim Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-13 Towíng . . . . . . . . . . . . . . . . . . . . . . . . . . . . .010-13 Spare Parts Kit . . . . . . . . . . . . . . . . . . . . . . . 010-14 TABLES

a. General Bolt Tightening Torques

in Nm (max . permissible) . . . . . . . . . . . . . . . . . . . . 010-5

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 010-7

GENERAL 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 average 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 '

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 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 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 Emergencies, including basic troubleshooting and information on how to gauge the seriousness of a problem .

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

010-2

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

HOW TO USE THIS MANUAL The manual is divided into nine sections : 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-ItYourself 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 Engine-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 corresponding 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 group system . For example, you can expect to find repair information on brakes (Repair Group 340) beginning on page 3401 . 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 likely to cause ínjury, eitherby dírect threat to the person(s) pertorming the work or by increased risk of accident or mechanfcal fallure whíle driving. CAUTIONA 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

NOTEA note contains helpful information, tips that will hefp in doing a better job and completing !t more easíly.

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 .

Safety Although an automobile presents many hazards, common sense and good equipment can helo ensure safety. Many accidents 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 secure 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 anythlng that is electrically powered. Accidental electrícal contact may damage the electrical system or cause a fire.

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

010- 3

WARNING " Never work under a lifted car unless it is solidly supported on jack stands that are intended for that purpose. Do not support a car on cinder blocks, bricks, or other objects that may shift or crumble under continuous load. Never work undera car that is supported only by the lifting jack. " Fuel is highly flammable. When working around fuel, do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy. " llluminate the work area adequately and safely. Use a portable safety light for working inside or under the car. A fluorescent type light is best because it gives off less heat. If using a light with a normal incandescent butb, use rough service bulbs to avoid breakage. The hot filament of an accidentallybroken bulb can ignite spilled fuel or oil " Keep sparks, lighted matches, and any open llame away from the top of the battery. Hydrogen gas emitted by the battery is highly flammable. Any nearby source of ignition may cause the battery to explode.

Fig. 1. 3-Series jacking points (arrows) .

Raising car safely 1 . Park car on flat, leve¡ su rface. 2. Remove the round cover from jack mount using a screwdriver. See Fig. 2.

" Never ¡ay tools or parts in the engine compartment or on top of the battery. They may fall into confined spaces and be difficult to retrieve, become caught in beits or other rotating parts when the engine is started, or cause electrical shorts and damage to the electrical system. " The fuel system is designed to retain pressure even when the ignition is off. When working with the fuel system, loosen the fuel fines slowly to allow the residual pressure to dissipate gradually. Take precautions to avoid spraying fuel.

Lifting the Car For those repairsthat require raising the car, the proper jacking points should be used to raise the car safely and avoid damage. There are four jacking points from which the car can be safely raised . The jack supplied with the car by BMW can only be used at the four side pointsjust behind the front wheel or just in front of the rear wheel. See Fig. 1 . WARNING " When raising the car using a floor jack or a hydraulic lift, carefully position the jack pad to prevent damaging the car body. A suitable liner (wood, rubber, etc .) should be placed between the jack and the car to prevent body damage .

Fig. 2. Jack mount cover being removed from rocker panel.

0013126

3. Place jack fully into position . See Fig. 3. Make sure jack is resting on flat, solid ground . Use a board or other support to provide a firm surface for the jack, if necessary. 4. Raise car slowly while constantly checking position of jack and car. 5. Once car is raised, block the wheel that is opposite and farthest from jack to prevent car from unexpectedly rolling .

" Watch the jack closely. Make sure ft stays stable and does not shift or tilt. As the car is raised, the car may rol¡ slightly and the jack may shift.

GET77NG STARTER

010-4

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER 4 . Place jack stands on firm, solid surface. If necessary, use a flat board or similar solid object to provide a firm footing. 5. Lower car slowly until its weight is fully supported by jack stands . Watch to make sure that the jack stands do not tip or lean as the car settles on them . 6. Observe all jacking precautions again when raising car to remove jack stands.

ADVICE FOR THE BEGINNER The tips in the paragraphs that follow are general advice to help any do-it-yourself BMW owner perform repairs and maintenance tasks more easily and more professionally .

Planning Ahead Fig. 3. BMW supplied jack correctly positioned in front jacking point.

WARNING" Do not rely on the transmission or the emergency brake to keep the car from rolling. They are not a substitute for positively blocking the opposite wheel. " Never work under a car that is supported only by a jack Use jack stands that are properly designed to support the car. See Tools.

Working under car safely 1 . Disconnect negative (-) cable from battery so that no one else can start the car. Let others know what you will be doing. CAUTION-

Prior to disconnecting the battery read the battery disconnection cautions given at the front of this manual on page vüi.

2. Raise car slowly as described above. 3. Use at least two jack stands to support the car. A jack is a temporary lifting device and should not be used alone to support the car while you are under it . Use jack stands designed for the purpose of supporting a car. For more information on jack stands, see Tools below. WARNING Do not use wood, concrete blocks, orbricks to support a car. Wood may split. Blocks or bricks, while strong, are not designed for that kind of load, and may brakk or collapse .

ADVICE FOR THE BEGINNER

Most of the repairs and maintenance tasks described in this manual can be successfully completed by anyone with basic tools and abilities. To prevent getting in too deep, know what the wholejob requires before starting . Read the procedure thoroughly, from beginning to end, in order to know just what to ex pect and what parts will have to be replaced .

Cleanliness Keeping things organized, neat, and clean is essential to doing a good job. When working under the hood, fender covers will protect the finish from scratches and other damage . Make sure the car is relatively clean so that di rt under the coverdoes not scratch the finish . Any repair job will be less troublesome if the parts are clean. For cleaning old parts, there are many solvents and parts cleaners commercially available. For cleaning parts prior to assembly, commercially available aerosol cans of parts cleaneror brake cleaner are handyto use, and the cleaner will evaporate completely. WARNING Virtually all solvents used for cleaning parts are highly flammable, especially in aerosol form . Use wíth extreme care. Do not smoke. Do not use these products near any source of heat, sparks or flame.

Let any solvent or cleaning product dry completely . Lowpressure, dry compressed air is helpful if available . Also, use only lint-free rags for cleaning and drying .

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

010-5

WARNING Avoid getting tools or clothing near the battery. Battery electrolyte is a corrosive acid. Be careful with brake fluid, as it can damage the cars paint Finally, keep rubber parts such as hoses and bolts free from oil orgasoline, as they will cause the material to soften and fail prematurely.

Non-reusable Fasteners Many fasteners used on the cars covered by this manual must be replaced with new oses once they are removed. These include but are not limited to : bolts, nuts (self-locking, nylock, etc.), cotter pins, studs, brake fittings, rol¡ pins, clips and washers. Genuine BMW parts should be the only replacement parts used for this purpose. Some bolts are designed to stretch during assembly and are permanently altered rendering them unreliable once removed. These are known as torque-to-yield fasteners. Always replace fasteners where instructed to do so . Failure to replace these fasteners could cause vehicle damage and personal injury . See an authorized BMW dealer for applications and ordering information .

Fig. 4. General sequence for alternately tightening multiple fasteners. NOTE" Metric bolt classes or grades are marked on the bolt' head. " Do not confuse wrench size with bolt diameter size. For a listing of the common wrenches used on various bolt diameters, see Basic Tool Requirements.

Table a. General Bolt Tightening Torques in Nm (max. permissible) Bolt Class (according to DIN 267)

Tightening Fasteners

Bolt diameter

5 .6

5 .8

6 .8

8.8

10 .9

12 .9

When tightening the bolts or nuts that attach a component, it is always good practice to tighten the boltsgradually and evenly to avoid misalignment or over stressing any one portion of the component. For components sealed with gaskets, this method helpsto ensure that the gasket will seal properly and completely .

2 .5

3 .5

4 .5

7 .5

15 -

M10

M12

115

140

M14

130

180

220

M16

150

200

280

340

M18

130

174

210

280

390

470

Where there are severa¡ fasteners, tighten them in a sequence alternating between opposite sides of the component. Fig . 4 shows such a sequence for tightening six bolts attaching a typical component. Repeat the sequence until al¡ the bolts are evenly tightened to the proper specification. For some repairs a specific tightening sequence is necessary, or a particular order of assembly is required . Such special conditions are noted in the text, and the necessary sequence is described or illustrated. Where no specific torque is listed, Table a can be used as a general guide for tightening fasteners. WARNING Table a is a general reference only. The values listed the table are not intended to be used as a substitute for torques specifically called out in the text throughout this manual.

Gaskets and Seals The smoothest metal mating surfaces still have imperfec tions that can allow leakage. To prevent leakage at critica¡ joints, gaskets of soft, form-fitting material are used to fill in the imperfections . To be most effective, gaskets are designed to crush and become thinner as the mating parts are bolted together . Once a gasket has been used, it is no longer capable of making as good a sea¡ as when new, and is much more likely to leak. For this reason, gaskets should not be reused . Always plan to use new gaskets for any reassembly. Some gaskets-such as head gaskets-are directional . Make sure that these are installed correctly . This same logic applies to any part used for sealing, including rubber O-rings and copper sealing washers.

ADVICE FOR THE BEGINNER

010-6

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

In places where a shaft must pass through a housing, flexible lip seals are used to keep the lubricating oil or grease from leaking out past the rotating shaft. Seals should never be reused once they have been removed. When removing a seal, be careful not lo scratch or otherwise damage the metal surfaces. Even minor damage to sealing surfaces can cause sea¡ damage and leakage.

Wire Repairs

The key to sea¡ installation is to get the sea¡ in straight without damaging ¡t. Use a sea¡ driver that is the same diameter as the seal housing to gently and evenly insta¡I into place. If a proper size seal driver is not available, a socket of the right size will do .

Use connectors that are designed for the purpose. Crimpedon or soldered-on connectors are best. Crimp connectors and special crimping pliers are widely available. If soldering, use needlenose pliers to hold the wire near the solder joint and create a "heat dam" . This keeps the heat and the solder from traveling up the wire . Always use a solder made specifically for electrical work (rosin core).

When installing a seal, ¡t a good idea to coat the sea¡ with o¡I to aid installation . Some seals are directional and special installation instructions apply. Make sure ¡t is installed with the lip facing the correct way. Normally the lip faces the inside. Note the installation direction of the old sea¡ before removing ¡t.

Electrical Testing Many electrical problems can be understood and solved with only a little fundamental knowledge of how electrical circuits function .

Electric current only flows in a complete circuit . To operate, every electrical device in the car requires a complete circuit including a voltage source and a path to ground . The positive (+) side of the battery is the original voltage source, and ground is any retum path to the negative - side of th e battery° whether ( ) through the wiring harness or the car body . Except for portions of the charging system, al¡ electrical current in the car is direct current (DC) and flows from positive (+) to negative (-). Switches are used to turn components on or off by completing or interrupting #he circuit . A switch is "open" when the circuit is ínterrupted, and "closed" when the circuit is completed. Fig. 5 shows a basic circuit schematic. See 600 Electrical SystemGeneral for electrical troubleshooting.

Repairs to a wiring harness require special care to make the repair permanent.The wire ends must be clean. lf frayed or otherwise damaged, cutoff the end. If the wire is too short, splice in a new piece of wire of the same size and make two connections.

NOTETwisting wires together to make a repair is not recommended. Corrosion and vibration will eventually spoil the connection and may lead to irreparable damage to sensitive electronic componente.

Insulate the finished connection . Electronics stores can supply heat-shrinkable insulating tubing that can be placed onto the wire before connectiog, slid over the finished joint, and shrunk to a tight fit with a heat gun or hair dryer. The next best alternative is electrical tape . Make sure the wire is clean and free of solder flux or other contamination. Wrap the joint tightly to sea¡ out moisture . See 600 Electrical-General for more information.

BVYING PART$ Many of the maíntenance and repair tasks in this manual cal¡ for the installation of new parte, or the use of new gaskets and other materials when reinstalling parts. Most often, the parts that will be needed should be on hand before beginning the job. Read the introductory text and the complete procedure to determine which parts will be needed . NOTEFor some bigger jobs, partial disassembly and inspection are required to determine a complete parts list. Read the procedure carefully and, if necessary, make other arrangements to get the necessary parts while your car is disassembled.

Genuine BMW Parts

B029ELG

Fig. 5. Schematic representation of simple circuit for light bulb . Ignition switch is shown closed, making circuit complete .

Genuine BMW replacement parts from an authorized BMW dealer are designed and manufactured lo the same high standards as the original parts. They will be the correct material, manufactured to the same specifications, and guaranteed lo fit and work as intended by the engineers who designed the car. Some genuine BMW parts have a limited warranty.

BVYING PARTS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER Many independent repair shops make a point of using genuine BMW parts, even though they may at times be more expensive . They know the value of doing the job right with the right parts. Parts from other sources can be as good, particularly if manufactured by one of BMWs original equipment suppliers, but it is often difficult to know . BMW is constantly updating and improving their cars, often making improvements during a given model year. BMW may recommend a newer, improved part as a replacement, and your authorized dealer's parts department will know about it and provide it . The BMW parts organization is best equipped to deal with any BMW parts needs.

Original body paneis and other large components are identified by a label bearing the VIN and two BMW roundel logos. Replacement parts have a similarlabel, bearing one BMW roundel logo and the letters DOT-R. See Fig. 6. Parts or assemblies bearing the label are the engine, transmission, front and rear bumpers, front fenders, rear quarter paneis, hood, trunk lid and doors. These labels should not be removed as they will tear apart.

)WBADK00000000 0

Non-returnable Parts Some parts cannot be returned for credit, even if they are the wrong parts for the car. The best example is electrical parts, which are almost universally considered non-returnable because they are so easily damaged internally . Buy electrícal parts carefully, and be as sure as possible that a replacement is needed, especially for expensive parts such as electronic control units. It may be wise to let an authorized BMW dealer or other qualified shop confirm your diagnosis before replacing an expensive part that cannot be retuned.

Information You Need to Know Model. When ordering parts it is important that you know the correct model designation for your car. Models covered in this manual are E36 3 Series in both 4- and 6-cylinder configurations. Moda¡ Year. This is not necessarily the same as date of manufacture or date of sale . A 1997 model may have been manufactured in late 1996, and perhaps not sold until early 1997. It is still a 1997 model. Model years covered by this manual are 1992 to 1998 . Date of Manufacture. This information is helpful when ordering replacement parts or determining if any of the warranty recalls are applicable to your car. The label on the driver's door belowthe door latch will specifythe month and year that the car was built. Vehicle Identification Number (VIN). This is a combination of letters and numbers that identify the particular car. The VIN appears on the state registration document, and on the car itself. One location is in the rear of the engine compartment, enother in the lower left comer of the windshield . The National Highway Traffic Safety Administration (NHTSA) requires passenger cars with a high theft rate to have the VIN marked on specific parts of the car when manufactured . On BMW cars, these parts are identified by an adhesive label.

010-7

000

DOT~ R

,.. PB328FUN

Fig. 6. Labels used to identiy parts. Original equipment label with VIN number and roundel logos (top) and replacement part label with one roundel logos Engine. 3-Series cars covered in this manual are powered by either a 4- or 6-cylinder engine . For information -on engine codes and engine applications, see 100 Engine-General . Transmission . The transmission type with its identifying code may be important when buying clutch parts, seals, gas kets, and other transmission-related parts. For information on transmission codes and applications, see 200 Transmission General.

SERVICE BMW dealers are uniquely qualified to provide service for BMW cars . Their authorized relationship with the large BMW service organization means that they are constantly receiving new tools and equipment, together with the latest and most accurate repair information . The BMW dealers service technicians are highlytrained and very capable. Unfke most independent repair shops, authorized BMW dealers are intensely committed to supporting the BMW product. They share the owners interest in BMW value, performance, and reliability. On the other hand, there are many independent shops that specialize in BMW service and are capable of doing high quality repair work. Checking with other BMW owners for recommendations on service facilities is a good wayto leam of reputable BMW shops in your area .

SERVICE

010- 8

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

TOOLS Most maintenance can be accomplished with a small selection of the right tools. Tools range in quality from inexpensive junk, which may brakk at first use, to very expensive and wellmade tools for the professional . The best tools for most do-it yourself BMW owners He somewhere in between.

Many reputable tool manufacturers offer good quality, moderately priced tools with a lifetime guarantee. These are your best buy. They cost a little more, but they are good quality tools that will do what is expected of them . Sears' Craftsman® line is one such source of good quality tools. Some of the repairs covered in this manual require the use of special tools, such as a custom puller or specialized electrical test equipment. These special tools are called out in the text and can be purchased through an authorized BMW dealer . As an alternative, some special tools mentioned may be purchased from the following tool manufacturers andlor distributors :

B005FNG

Fig. 7. Common flat-blade (top) and Phillips (bottom) screwdrivers . Offset screwdríver (right) is used for screws with limited access.

" Assenmacher Specialty Tools 6440 Odell Place, Boulder, CO 80301 (303) 530-2424

" Baum Tools Unlimited. Inc. PO. Box 87, Longboat Key, FL 34228 (800) 848-6657

" Schley Products Inc. 5350 E . Hunter Ave., Anaheim Hills, CA 92807 (714) 693-7666

" Zelenda Machine and Tool Corp . 66-02 Austin Street, Forest Hills, NY 11375 (718) 896-2288

Basic Tool Requirements The basic hand tools described below can be used to accomplish most of the simple maintenance and repair tasks. Screwdrivers . The common fíat-blade type and the Phillips type will handle almost all screws used on BMWs . Two orthree different sizes of each type will be required, since a screwdriver of the wrong size will damage the screw head. See Fig. 7. A complete set of screwdrivers should also include Torx@ type screwdrivers . Wrenches . Wrenches come in different styles for different uses . Fig. 8 shows several . The basic open-end wrench is the most widely used, but grips on only two sides. It can spread apart and slip off more easily . The box-end wrench has better grip, on al¡ six sides of a nut or bolt. A 12-point box-end can loosen a nut or bolt where there is less room for movement, while a 6-point box-end provides bettergrip . For hex fasteners on fluid lines, like brake lines and fuel lines, a fiare-nut wrench offers the acivantages of a box-end wrench with a slot that ailows it to fit over the line . TOOLS

B002FNG

Fig. 8. Types of wrench heads . From left, open-end, 12-point boxend, 6-point box-end, fiare nut. The cómbination wrench is the most universal . It has one open-end and one box-end. 10mm and 13mm wrenches are the most common sizes needed . A more complete set of wrenches would inciude 6mm through 19mm sizes. Sockets. Sockets perform the same job as box-end wrenches, but offer greater flexibility. They are used with a ratchet handle for speed and conveniente and can be combined with extensions and universal joints (swivels) to reach fasteners more easily . Sockets come with different size connections to drive handies or extensions, called the drive size . The most common drive sizes are 1/4 in ., 318 in ., and 1/2 in . Sockets come in 6-point and 12-point styles . For use with a ratchet, the 6-point offers a better grip on tight nuts and bolts. 6mm to 19mm sockets are the most needed sizes. Below is a list of typical bolt diameters and the corresponding wrench sizes .

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER Solt Diameter and Wrench Size " M5 . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 8 mm " M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 mm " M8 . . . . . . . . . . . . . . . . . . . . . . . . . 12mmor13mm " M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 mm " M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 mm " M14 . . . : . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 mm Spark Plug Socket . A special socket for spark plugs is the correct size, is deep enough to accommodate a spark plug's length, and includes a rubber insert to both protect the spark plug from damage and grip it for easier removal. See Fig. 9.

010-9

Snap-ring and circlip pliers with special tipped jacas are used lo remove and install snap-rings or circlips . A Channel-lock® or water pump plier has adjustable jacas that can be quickly changed to match the size of the object being held to give greaterleverage . An adjustable wrench can be a useful addition to a small tool kit. See Fig. 11 . It can substitute in a pinch, if two wrenches of the same size are needed lo remove a nut and bolt . Use extra care with adjustable wrenches, as they tend to loosen, slip, and damage fasteners.

B008FNG

Fig. 11 . Adjustable wrench . Compared to a wrench of the correct size, an adjustable wrench is always second best. They should only be used when the correct size wrench is not available. Choose one of average size range, about 6 to 8 inches in length . B003FNG

Fig. 9. Spark plug socket . Pliers . A fewof the many types of pliers are shown in Fig. 10 . Most are used for holding irregular objects, bending, or crimping. Some have special applications .

Jack Stands Strong jack stands are extremely important for any work that is done under the car. Use only jack stands that are designed for the purpose. Blocks of wood, concrete, bricks, etc. are not safe or suitable substitutes . WARNING A jack should be used only to raise the vehicle and should not be used to support the car for a long period. Always use jack stands to support a raised vehicle.

Jack stands are available 1n severa¡ styles . A typical jack stand is shown in Fig . 12 . The best ones are made of heavy material for strength, have a wide base for stability, and are equipped lo positively lock in their raised positions. Get the best ones available. Oil Change Equipment BOO6FNG-

Fig. 10 . Pliers . From left, snap-ring, needlenose, adjustable-joint (Channellock©), slip-joint, and locking (Vise-Grip®) .

Changing engine oil requires a 17mm socket or wrench to loosen and tighten the drain plug and a drain pan (at least 8 qt . capacity) . An oil filter wrench is not required . These items are shown in Fig. 13 . A wide, loca drain pan wíll fit more easily under the car. Use a funnel lo pour the new oil into the engine .

A needlenose plier is used for gripping small and poorly accessible objects, and is useful for wiring and other electrical work. A locking plier such as the Vise-Grip® is useful because of its tight grip . TOOLS

010-10

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

B018FNG

B021FNG

Fig. 12 . Jack stand for safely supporting car to work underneath .

Fig. 14 . Torque wrenches . Inexpensive beam-type (top) is adequate but must be read visually. Ratchet-type (bottom) can be preset to índicate (click) when torque value has been reached.

Feeler Gauges Feeler gauges are thin metal strips of precise thickness, used to measure small clearances . They are normally available as a set, covering a range of sizes. See Fig. 15 .

B022FNG

Fig. 13 . Oil change equipment includes drain plug wrench (17mm), 8 qt . drain pan, and funnel . B020FNG

Torque Wrench Atorque wrench is used to preciselytighten threaded fasteners to a predetermined value. Many of the repair procedures in this manual include BMW-specified torque values in Newtonmeters (Nm) and the equivalent values in foot-pounds (ft-Ib). Several types of torque wrenches are available . They al¡ do the same job, bu¡óffer different convenience features at different prices . Two typical torque wrenches are shown in Fig. 14 . The most convenient ones have a built-in ratchet, and can be preset to indicate when a specific torque value has been reached. Follow the wrench manufacturer's directions for use to achieve the greatest accuracy . A torque wrench with a range up to about 150 Nm (185 ft-lb)

has adequate capacity for most of the repairs covered in this manual . For recommended torque values of 10 Nm or below, the English system equivalent is given in inch-pounds (in-lb) . These small values may be most easily reached using a torque wrench calibrated in inch-pounds . To convert inch-pounds to foot-pounds, divide by 12 . TOOLS

Fig. 15 . Feeler gauge set.

Digital Multimeter Many of the electrical tests in Chis manual cal¡ for the measurement of resistance (ohms) or voltage values . For safe and accurate tests of ignition, fuel injection, and emission control systems, the multi-meter, shown in Fig. 16, should be digital, with high (at least 10,000 ohms) input impedance. Some meters have automotive functions such as dweil and pulse width that are useful fortroubleshooting ignition and fuel injection problems . CAUTION-

The DME system, central body electronics, and other electronic systems may be damaged by the high current draw of a test fight with a normal incandescent bulb. As a general rule, use a high ímpedance digital multimeter or an LED test fight for all electrfcal testfng.

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

01 0-11

wheel (wheel chock located in trunk) diagonally opposite to the one being changed. Passengers should get out of the car and stand well away from the road . Remove the spare tire from the spare tire storage tray, as described later. WARNING If a tire goes fíat while drtving, pull well off the road. Changing a tire on a busy street or highway is very dangerous . If necessary, drive a short distance on the fíat tire to get to a sale place . tt is much better to ruin a tire or rim than to risk being hit.

Take the jack and tools from the tool area beneath the trunk mat. Remove the spare tire from the tire storage tray. Loosen the wheel bolts while the car is on the ground, but leavethem a little snug. Placethejack in the lifting point nearest the wheel being changed, lifting points are shown in Fig. 1 and Fig. 2) . Use a board to provide a firm footing for the jack if the ground is soft . Raisethe caronly lar enough so that the wheel is fully off the ground and then remove the wheel nuts and the wheel.

0012223

Fig. 16 . Multimeter or Digital Volt/Ohmmeter (DVOM) .

BMW Special Tools Some of the more challenging repairs covered in this manual cal¡ for the use of BMW special tools. This, however, does not automatically mean that the job is too complicated or out of reach of the novice . Many of the BMW special tools mentioned in this manual are simply the best thingto useto do the jobcorrectly. In these cases, the tool is identified with a BMW part number . See your authorized BMW dealer parts department for information on how to order special tools. There are some jobs for which expensive special tools are essential, and not a cost-effective purchase for one-time repair by the do-it-yourself owner. This manual includes such repairs for the benefit of these with the necessary experience and access to tools. Forthe do-it-yourselfer, the need for special tools is noted in the text, and whether or not BMW dealer service is recommended.

EMERGENCIES Changing a Tire Stop the car on as flat a surface as possible, in a place where you can be easily seen by other drivers. Avoid stopping just over the crest of a hill . Turn on the emergency flashers, and set out (lares or emergency markers well behind the car. Chock the

Insta¡¡ the spare wheel. Install the wheel nuts and tighten them by hand, then lower the car. With all wheels on the ground, fullytighten the nuts in a crisscross pattern. Torque the wheel nuts when installing the wheel . Check the inflation pressure of the spare tire . Tightening torques " Wheel to wheel hub . . . . . 100 t 10 Nm (74 t 7 ft-Ib)

Car Will Not Start If the engine tucos over slowly or not at all, especially on cold mornings, the battery may not be sufficiently charged. Jumpstarting the battery from another car may help. WARNING On cars with manual transmisston, push starting (or tow starting) a car ts not recommended by BMW. NOTEBe sure to read the cautions underJump Starting Car prior boosting a low battery. Fatlure to follow the cautions may result in damage to the electronic components in the car.

If the engine is turning over at normal speed with the starter motor, the battery and starter are fine . Check to make sure that there is fuel in the tank . Do not rely on the fuel gauge, it may be faulty . Instead, remove the gas filler cap and rock the car. If there is gas in the tank, you should hear a sloshing sound at the filler neck . lf there is plenty of fuel in the tank, see 100 EngineGeneral for in-depth diagnostics and troubleshooting procedures. EMERGENCIES

010-12

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER

Jump Starting Car Cars with discharged or dead batteries can be jump-started using the good battery from another car. When jump-starting the engine, always note the following warnings. WARNING " Battery acid (electrolyte) can cause severe burns, and will damage the car and clothing . lf electrolyte is spilled, wash the surface with large quantities of water. lf it gets finto eyes, flush them with water for severa¡ minutes and cal¡ a doctor. " Batteries produce explosive and noxious gasses. Keep sparks and flames away. Do not smoke near batteries.

you

" Do not jump-start the engine if suspect that the battery is frozen. Trapped gas may explode. Allow the battery to thaw first. " Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 15 volts at the battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time . " Some electrical system 'comfort" features may not function correctly once battery power is restored. For example, the front window one-touch-up function may be disabled. Some electrical systems will need to be reinitialized Consult the appropriate repairgroup formore specific information.

1 . Place cars close together, but do not allow them to 'touch each other. Turn off the engine of the car with the good battery. 2. Connect one end of the positive (+) cable to the positive (+) post of the good battery. Remove the coverfrom the positive (B+) junction post in the engine compartment of the dead car and connect the other end of the positive (+) cable to the junction post. See Fig. 17 .

3. Connect one end of the negative (-) cable to the negative (-) battery post of the good battery. Connect opposite end of the negative cable (-) to the engine block of the car with the dead battery. 4. Start the car with the good battery and run the engine at about 2,000 rpm, then startthe car with the dead battery. 5. With the engine at ¡dle, switch on the headlights, blower motor and rear window defogger to avoid damaging the cars electrical system . Carefully disconnect the jumper cables, starting with the negative cable on the engine block. Turn all electrical consumers off. NOTEThe engine should be run for at least an hour to recharge the battery.

Overheating lf the temperature gauge needle goes into the red band on the gauge face, the coolant temperature is too high . Find a safe place to stop and turn the engine off. Open the hood and allow the engine to cool until the temperature gauge needle is at the lower third of the scale. Continuing to drive an overheated car can cause extensive engine damage . WARNING Do not remove the coolant reservoir or radíator cap with the engine hot. Undoing either could spray hot coolant and cause burns or damage the engine. CAUTIONDo not add cold water or coolant to a hot engine. Engine damage could result from the sudden temperature change . NOTEIf the engine cannot be safely tumed off, make sure the air condifioner is off and turn the heater to high . This will helo cool the engine until a sale stopping place can be reached.

Overheating may be caused by low coolant leve¡ or a damaged engine drive belt. Visually check the coolant leve¡ and engine belts as described in 020 Maintenance Program. lf the coolant leve¡ is low, check the filler cap, hoses, clamps and radiator for signs of leakage. Check for leaks at the water pump on the front of the engine .

0013245

Fig. 17 . Battery jump starting posts (arrows) behind right front strut tower. Lift cover to access positive post .

EMERGENCIES

lf no leaks are found, add coolant after the engine has cooled . The car can be driven, but have the cooling system thoroughly checked as soon as possible . lf replacement cool ant is not available, then plain water can be used, but the coolant should later be drained and refilled with the proper mixture of anti-freeze and water.

FUNDAMENTALS FOR THE DO-IT YOURSELF OWNER If steam is coming from the engine compartment thenthere is most likely a burst coolant hose or a large leak in the cooling system . To find the leak, look for signs of coolant leakage on hoses, at hose connections, or on the radiator. Let the engine cool thoroughly, then add coolant or water to fill the system and start the engine. If a great deal of water or coolant flows out of the hole, then the car should not be driven until repairs are made . lf there is slight seepage, then it may be possible to drive a short distance, adding coolant as needed .

Low Oil Pressure If the red engine oil pressure warning light illuminates, immediately stop the car and turn off the engine . Have the vehicle flat-bedded or towed to an authorized service center and have the engine oil pressure checked.

01 0-13

With the engine and ignition off, check for loose or corroded battery cables or wires at the battery or the altemator. Disconnecting, cleaning, and reinstalling corroded wires and connectors may solve the problem. Also check drive belt tension as described in 020 Maintenance Program. TOWi ng The cars covered by this manual should be towed with a tow truck using wheel lift or flat bed equipment. Do not tow the car on all four wheels except forvery short distances to move it to a safe place. A towing eye is provided in the luggage compartment tool kit . The towing eye can be screwed into the front or rear bumper . See Fig. 18 and Fig. 19 .

NOTEDetafed information on checking the oil pressure is covered ín 119 Lubrication System .

Brake Fluid Leve¡ The brake fluid leve¡ warning light may be an indicator of brake fluid loss. Problems with the brake system should be checked and repaired immediately . See 340 Brakes for more information .

Check Engine Warning Light If the "CHECK ENGI NE" warning light comes on or flashes, it indicates that an emissions-related fault has occurred . Faults such as a failed oxygen sensor or a faulty fuel injector can tum the light on, causing the exhaust or evaporative emissions to exceed a specified limit. The engine can be safely driven with the light on, although the emission systems should be checked as soon as possible . See 100 Engine-General for more information on the Check Engine Light and the On-board diagnostic system .

Dim Lights Headlights and instrument panel illumination that are dim or gradually getting dimmer generally indicate a problem with the battery or charging system . The battery charge indicator light may come on as the lights are dimming. In either case, the engine and accessories are running off of the battery alone, and will soon discharge it altogether. If possible, do not stop the engine unless you have the capability to jump start ¡t. There may not be enough power in the starting system to restart the engine . Instead, turn off as many electrical consumers as possible . This will reduce the current drain and will allow the car to be driven farther before you lose all battery power.

0013128

Fig. 18. Pry open rear tow lúg access panel .

When towing the car from the front with the rear wheels on the ground, a maximum distance of 20 miles is acceptable . If the car needs to be towed further, have the rear wheels placed on dollies. CA UTION" Do not tow with sling-type equipment The front spoilers and bumper covers may sustain damage. " Towíng a BMW with an automatic transmission with the rear wheels on the ground can resuft in transmission damage due to lack of lubrication and should be avoided.

EMERGENCIES

010-14

FUNDAMENTALS FOR THE DO-ITYOURSELF OWNER Spare Parts Kit Carrying a basic set of spare parts can prevent a minor breakdown from turning into a major annoyance. Many of the following items won't allow you todo major repair work on the car, but they will help in the event of the failure of something that can disable the car or compromise its safety . Spare Parts Kit - Basic Contents " Drive belt (V-belt or poly-ribbed) " Engine oil (one or two quarts) " Engine coolant (1 gallon of premixed 50/50 anti-freeze and water) " Fuse assortment (7 .5A, 10A, 15A, 20A) " Radiator hoses (upper and lower) Spare Parts Kit - Additional Contents " Exterior lighting bulbs (headlight, brakelight, turn signal, and taillight) " Wiper biades " Brake fluid (new unopened bottle, DOT 4 specification) " Main relay for DME system

Fig. 19. Instaf rear tow lug into threaded hole .

úo1W¿b

if absolutely necessary, cars with automatic transmissions can be towed with the rear wheels on the ground, but the tow should not exceed 25 miles (40 km), at speeds at or below 30 mph (35 km/h). Be sure the transmission fluid has been topped off before starting the tow. Always towthe car with thetransmission lever in "N" (neutral). If the tow must exceed 25 miles (40 km), add one quart of ATF to the transmission, or better yet, remove the driveshaft . Be sure to drain or pump out the addedfluid once the tow has been completed. NOTE" ATF draining and filling is covered in 240 Automatic

Transmission.

" Driveshaft removal is covered in 260 Driveshaft.

EMERGENCIES

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

MAINTENANCE PROGRAM

020-1

020 Maintenance Program GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-2 BMW Service Indicator . . . . . . . . . . . . . . . . . . . . 020-2 Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-2 Inspection I and Inspection II . . . . . . . . . . . . . . . 020-2 Resetting Service Indicator. . . . . . . . . . . . . . . . . 020-3 MAINTENANCE TABLES . . . . . . . . . . . . . . . 020-3 FLUID AND LUBRICANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 020-8 Manual Transmission Fluid . . . . . . . . . . . . . . . 020-8 Automatic Transmission Fluid . . . . . . . . . . . . . 020-8 Final Drive Gear Oil . . . . . . . . . . . . . . . . . . . . 020-9 Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . 020-9 Engine Coolant (Anti-freeze) . . . . . . . . . . . . . . 020-9 Power Steering Fluid . . . . . . . . . . . . . . . . . . . . 020-9

ENGINE OIL SERVICE . . . . . . . . . . . . . . . . . 020-9 Engine oil, checking leve¡ . . . . . . . . . . . . . . . . . . 020-9 Engine oil and filter, changing . . . . . . . . . . . . . . 020-9 ENGINE COMPARTMENT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . 020-10 Air filter, replacing . . . . . . . . . . . . . . . . . . . . . . . 020-11 Spark plugs, replacing . . . . . . . . . . . . . . . . . . . 020-11 ¡dle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-12 Battery, checking and cleaning . . . . . . . . . . . . 020-12 Battery, replacing . . . . . . . . . . . . . . . . . . . . . . . 020-12 Accelerator and Throttle Linkage . . . . . . . . . . . 020-13 Engine Drive Belts . . . . . . . . . . . . . . . . . . . . . . 020-13 V-belt, replacing (4-cylinder engines built up to 1/94) . . . . . . . 020-13 Poly-ribbed belt, replacing (4-cylinder engines built from 1194 and all 6-cylinder engines) . . . . . . . . . . . . . . 020-13 Cooling System Service . . . . . . . . . . . . . . . . . . 020-14 Power steering fluid, checking leve¡ . . . . . . . . . 020-14 Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . 020-15

UNDER-CAR MAINTENANCE . . . . . . . . . .020-16 ' Fuel filter, replacing . . . . . . . . . . . . . . . . . . . . .020-16 Tires, checking inflation pressure . . . . . . . . . . . 020-17 Tires, rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-17 Wheels, aligning . . . . . . . . . . . . . . . . . . . . . . . . '020-17 Brake system, inspecting . . . . . . . . . . . . . . . . . 020-17 Brake pad/rotor wear, checking . . . . . . . . . . . . 020-17 Brake fluid, replacing . . . . . . . . . . . . . . . . . 020-17 Parking brake, checking . . . . . . . . . . . . . . . . . . 020-17 Exhaust system, inspecting . . . . . . . . . . . . . . . .020-18 Manual Transmission Senrice . . . . . . . . . . . . . . 020-18 Manual transmission fluida checking and filling . . . . . . . . . . .. . . . . . . . 020-18 Automatic Transmission Service . . . . . . . . . . . . 020-18 Front suspension and steering linkages, inspecting . . . : . . . . . . . . . . . . . . . . . . . . . . . .020-18 Rear suspension, inspecting . . . . . . . . . . . . . . . 020-18 Final drive oil leve¡, checking. . . . . . . . . . . . . . . 020-18 Fuel tank and fuel lines, inspecting . . . . . . . . . . 020-19 Clutch fluid, checking . . . . . . . . . . . . . . . . . . . . . 020-19 Drive axle joint boots, inspecting . . . . . . . . . . . . 020-19 BODY AND INTERIOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .020-19 Windshield Wiper Blade Maintenance . . . . . . 020-19 Body and hinges, lubricating . . . . . . . . . . . . . . . 020-19 Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-20 Exterior Washing . . . . . . . . . . . . . . . . . . . . . . . .020-20 Waxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-20 Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .'020-20 Washing Chassis . . . . . . . . . . . . . . . . . . . . . . . . 020-20 Special Cleaning . . . . . . . . . . . . . . . . . . . . . . .020-20 Interior Care . . . . . . . . . . . . . . . . . . . . . . . . . . . 020-20 Leather Upholstery and Trim . . . . . . . . . . . . . . . 020-20 TABLES

a. Oil Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . --- 020-4 b . Inspection 1 Service . . . . . . . . . . . . . . . . . . . . . . . . 020-5 c. Inspection 11 Service . . . . . . . . . . . . . . . . . . . . . . . 020-6 d. Scheduled Maintenance-Time/Mileage Intervals . . 020-7 e. Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . 020-8

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

020-2

MAINTENANCE PROGRAM

GENERAL The information given in this repair group includes the routine checks and maintenance steps that are both required by BMW under the terms of the vehicle warranty protection and recommended by BMW to ensure long and reliable vehicle operation. NOTEAside from keeping your car in the best possible condition, proper maintenance plays a role in maintaining full protection under BMWs new-car warranty coverage. If in doubt about the terms and conditions of your cark warranty, an authorized BMW dealer should be able to explain them .

BMW has taken a unique approach to establishing maintenance intervals. BMW's Service Indicator System computes maintenance intervais based not only on elapsed mileage, but also on such inputs as engine speed, engine temperature, number of starts, and length of trips . At the appropriate time, the system indicates, through lights in the instrument cluster, when the next routine maintenance is due. NOTEBMW is constantly updating their recommended maintenance procedures and requirements. The information contained here is as accurate as possible at the time of publication . If hhere is any doubt about what procedures apply to a specific model or model year, or what intervals should be followed, remember that an authorized BMW dealer has the latest information on factory-recommended maintenance.

BMW Service Indicator The BMW Service Indicator notifies the driver when maintenance is required . The service indicator consísts of multiple light emitting diodes (lEDs)-typically five green, one yellow, and one red-as well as OIL SERVICE and INSPECTION indicators . When the ignition is tumed on, the green LEDs come on . They go out when the engine is started. After the Service Indicator is reset, al¡ green LEDs will be illuminated with the key on . As the car is driven in normal use, fewer and fewer green LEDs will be illuminated before start-up, indicating that the next maintenance interval is approaching . When the car has accumulated sufficient use to require the next maintenance interval, the yellow LED will come on along with either the OIL SERVICE indicator or the INSPECTION indicator. These LEDs will stay on after the engine is started. If maintenance service is delayed, the red LED will also illuminate as a reminder that maintenance service is overdue . An OIL SERVICE interval will always be followed by an INSPECTION interval, which will then be followed by an OIL SERVICE interval, and so on . See Fig. 1 . GENERAL

60 1,4

AO `F

, II 100/ " 1 140s # X120 `20 ló 100

80 ,~ 60 ,

km/h

leo

200 , *101

Fig. 1 . Service indicator display in lower section of speedometer.

Oil Service The Oil Service indicator signals the need for the most basic level of routine maintenance. BMW's required oil service specifies changing the engine lubricating oil and the engine oil filter afterthe engine has been warmed up . BMW-recommended additional maintenance for this service is listed in Table a. NOTEFor reference, the BMW Oil Service requirements are approximately equivalent to the maintenance that other European manufacturers specify at intervals with a maximum of every 7,500 miles or 6 months. CAUTIONBe sure to follow the ínstructions forresetting the Oil Service indicator fight. The Inspection indicator can be accidentally reset rendering its function inaccurate.

Inspection l and Inspection II The Inspection indicator signals the need for more comprehensive maintenance and Inspection . There are two sets of inspection requirements, Inspection I and Inspection ll . These inspections alternate throughout acar's maintenance history. If the last Inspection interval was Inspection I, the next Inspection interval (following an Oil Service) will be Inspection ll, the next after that will be Inspection I, and so on . Inspection I tasks are listed in Table b. Inspection II includes most of the tasks from Inspection I with additional Inspection 11 tasks. A complete listing of Inspection II tasks are listed in Table c.

MAINTENANCE PROGRAM NOTE-

For referente, the BMW Inspection 1 and Inspection 11 requirements are approximately equivalent to the maintenance requirements that other European manufacturers specify. Inspection I is normally due at intervals with a maximum of 15,000 miles or 12 months . lnspection 11 is normally due at intervals with a maximum of 30,000 miles or 24 months.

Resetting Service Indicator When the specified maintenance has been carried out, the service indicator memory should be reset. The senrice indicator is reset using a special tool . The tool is plugged into the diagnostic connector in the engine compartment . See Fig. 2.

020-3

Aftermarket reset tools can be purchased from one of the follift owng manuacurers : Assenmacher Specialty Tools Bos lder, CO 80301 (303) 530-2424 Peake Research, Automotive Products Division P.O . Box 28776 San Jose, CA 95159 (408) 369-0406

MAINTENANCE TABLES Table a, b, c, and d on the following pages list the routine maintenance tasks specified by BMW. The intervals for most of these tasks are determined by the Service Indicator. The maintenance intervals for a few additional items are based on either elapsed mileage or time . These intervals are indicated in separate tables . Except where noted, the maintenance items listed applyto all models and model years covered by this manual . The columns on the right sitie of each table give quick-referente information about the job. The bold text references the repair groups where additional repair information can be found.

iii Fig. 2. Service indicator reset tool installed in diagnostic connector (aftermarket tool shown) . CAUTION-

Follow the manufacturer's directions when resetting the service Indicator. If the reset procedures are done incorrectly, the reset tool or the electronic service indicator may be damaged.

MAINTENANCE TABLES

020-4

MAINTENANCE PROGRAM Table a. Oil Service

L L w

Maintenance ítem Engine compartment maintenance Change oil and oil filter Check fluid levels (coolant, steering, brake/clutch, ATF) Under car maintenance Check steering rack and steering linkages for leaks and excess play. Repair Group 320 Inspect brake system . Check brake calipers, rotors, and brake pad thíckness . Inspect for damaged hoses and lines, leaks or damage . Check hand brake, adjust cable if necessary. Repair Group 340 Check and adjust tire pressures, including spare Body and interior maintenance Check operation of exterior and interior lights, including glove box light, engine compartment light, trunk light, instrument panel lights, horns, headlight flasher and dimmer switch . Check headlight and driving light aiming . 6 Electrical System Check function/condition of seat belts . Repair Group 720 Check windshield washer fluid level and concentration, add as necessary. Check operation of washer system . Check condition of wiper blades . Repair Group 611 Road Test Check braking performance, steering, heating and ventilation, manual or automatic transmission, and mirrors Service Interval Reset Reset service indicator using special reset tool .

MAINTENANCE TABLES

~ a

~ .c a

~a> cm

~ L £ 'S

L E

MAINTENANCE PROGRAM

020-5

Table b. Inspection I Service a d

;v y Maintenance ítem Engine compartment maintenance

rL-

ra: z

cQ~

ID d a~ wE E

3~ cd

Change oil and oil filter. Check brake/clutch fluid leve¡ Check battery acid leve¡ and correct as necessary. Repair Group 121 Check engine coolant level and anti-freeze protection and add as necessary. Inspect for cooling system leaks. Repair Group 170 Lubricate throttie linkage Under car maintenance Check transmission for externa¡ leaks . Check manual transmission oil leve¡ and add as necessary. Repair Group 230 Check final drive lubricant and add as necessary. Check fue¡ tank, fuel lines, and all connections for leaks . Inspect exhaust system. Repair Group 180 Check steering rack and steering linkages . Check power steering system for leaks. Check (luid leve¡ . Repair Group 320 Inspect brake system for damaged hoses and fines, leaks or damage. Remove calipers and check brake pad wear. Check brake rotors for scoring damage . Repair Group 340 Check parking brake operation, adjust cable if necessary Repair Group 340 Inspect front and rear suspension, including wheel bearings, for play. Repair Group 320/330 Inspect wheels and tires, including spare, check tire pressure and condition Body and Interior Maintenance Lubricate door hinges and hood latch, hood hinges Check headlight and driving light aiming and adjust as necessary. Check operation of headlights, parking lights, back-up fights, license plate lights, interior lights, glove box light, engine compartment light, trunk light, instrument panel lights, turn signals, emergency flashers, stop fights, horas, headlight flasher and dimmer switch Replace ventilation/A/C micro-filter. Check function of air conditioning . Repair Group 640 Check function of seat belts . Repair Group 720 Check tightness of mountfng screws on airbag front crash sensors (Airbag I) . Repair Group 721 Check windshield washer fluid leve¡ and concentration, add as necessary Check operation of washer system . Check condition of wiper blades . Repair Group 611 Tighten nuts and bolts for door locks and striker plates Replace batteries for alarm/remote control in master key (where applicable) . Road Test Check braking performance, steering, HVAC, manual or automatic transmission, and mirrors Service Interval Reset Reset service indicator using special reset tool .

MAINTENANCE TALES

020-6

MAINTENANCE PROGRAM Table c. Inspection II Service a

Maintenance ítem Engine compartment maintenance

a L

lo -

.cm y E

0d m m L E

Inspect V-belt /Poly-ribbed drive condition . Check V-belt tension, if applicable . Lubricate throttle linkage . Replace air filter. Change oil and oil filter. Replace spark plugs. Repair Group 120 Check brake/clutch fluid leve¡ . Check battery acid leve¡ and correct as necessary. Repair Group 121 Check engine coolant leve¡ and anti-freeze protection and add as necessary. Inspect for cooling system leaks . Repair Group 170 Under car maintenance Change automatic transmission fluid . Repair Group 240 Change manual transmission oil . Repair Group 230 Check clutch plate for wear . Repair Group 210 Check drive axle boots for leaks . Repair Group 330 Change final drive fluid (1995 and later models : change synthetic oil every 2nd Inspection II). Replace fuel filter. Check fuel tank, fuel lines, and af connections for leaks . Inspect exhaust system . Repair Group 180 Check steering gear and steering ¡inkages. Check power steering system for leaks . Check fluid leve¡. Repair Group 320 Inspect brake system for damaged hoses and lines, leaks or damage . Remove calipers and check brake pad wear. Check brake rotors for scoring damage . Repair Group 340 Check parking brake operation, adjust cable if necessary. Check thickness of parking brake linings. Repair Group 340 Inspect front and rear suspension, including front and rear wheel bearings, for play. Repair Group 310/330 Inspect wheels and tires, including spare, check tire pressure and condition . Body and Interior Maintenance Lubricate door hinges and hood latch, hood hinges. Check headlight and driving light aiming and adjust as necessary. Check operation of headlights, parking lights, back-up lights, license plate lights, interior lights, glove box light, engine compartment light, trunk light, instrument panel lights, turn signals, emergency flashers, stop lights, horns, headlight flasher and dimmer switch . Check active check control panel for fauits (where applicable) . 6 Electrical System Continued on next page

MAINTENANCE TABLES

MAINTENANCE PROGRAM

020-7

Table c. Inspection II Service (continued) d

Maintenance ítem

a L

a. N N

<C O.

G1 Ñ

~ i

° I D i

G> G1 N d

Body and Interior Maintenance (cont.) Replace ventilation/A/C micro-filter. Check function of air conditioning . Repair Group 640 Check function of seat belts . Repair Group 720 Check windshield washer fluid level and concentration, add as necessary. Check operation of washer system . Check condition of wiper blades Repair Group 611 Tighten nuts and belts for door locks and striker plates. Replace batteries for alarm/remote control in master key (where applicable) . Check ground connection (mounting screws) of SRS (airbag) front sensor to body, if applicable . Repair Group 721 Road Test Check braking performance, steering, HVAC, manual or automatic transmission, and mirrors Service Interval Reset Reset service indicator using special reset tool .

Cable d. Scheduled Maintenance-Time/Mileage Intervais

e N r

Maintenance ítem

l= <C M

l " N

I Ó

«)

al N Ñ

aN y . Ñ

I` Ó

- 011 Ñ

° V

Replace oxygen sensor. Repair Group 180 1992-1994 1995- on Flush and replace brake fluid/clutch fluid. Repair Group 340 Drain and flush cooling system and replace coolant . Repair Group 170 1992-1996 1997-1998 Anti-corrosion warranty inspection .

MAÍNTENANCE TABLES

MAINTENANCE PROGRAM

020-8

Table e. Fluids and Lubricants (continued)

FLUID AND LUBRICANT SPECIFICATIONS

Fluid

Approximate Specification capacity Automatic transmission fluid (ATF) (drain and fill) (additional fluid required when installing a dry torque converter)

The fluids and lubricante specified by BMW are listed in Table e. Shown below is engine oil viscosity (SAE grade) vs . operating temperature range for the BMW engines covered in this manual .

A4S 310R See 240 Automatic Transmission for fluid A4S 270R specification information A5S 310Z Final drive (drain and fill) (Lifetime fluid ; no fluid change required) 4-cylinder 1 .1 I (1 .2 US qt .) BMW SAF-XO 6-cylinder 1 .7 l(1 .8 US qt .) synthetic oil (ex . limited slip) BMW SAF-X1-S synthetic oil (limited slip) Power steering fluid Al¡ modeis permanentlysealed Dexron IIPATF no drain plug rake fluid All modeis SAE Dot 4 Engine coolant M42 engine 6.51(6 .9 US qt .) M44 engine 6 .51(6 .9 US qt .) M50 engine 10 .51 (11 .1 US qt .) 50% BMW antiM52 engine 10 .5 1 (11 .1 US qt .) freezel 50% water S50US engine 10 .75 1(11 .4 qt.) S52US engine 10 .75 I (11 .4 qt.)

Engine Oil Viscosity Requirements vs. Temperature °F

`SEAVicP

SAE

swao

YCO

CA UTIONMulti-viscosity engine oils should not be used in the manual transmission . Use of such an oil could shorten the service life of the transmission.

-1o-0 30 -----20

Manual Transmission Fluid 0013227

The manual transmissions installed in the E36 modeis are normallyfilled with automatic transmission fluid (ATF), although alternative synthetic lubricants may have been used from - the factory, depending on transmission type and model year. Consult 230 Manual Transmission for additional information on identifying the type of fluid installed.

WARNING The use of fluids that do not meet BMWs specifications may impair performance and refability, and may void warranty coverage .

Fluid

Table e. Fluids and Lubricants

Approximate capacity Engine oil with filter change M42 engine 5 .01 (5.3 US qt .) M44 engine 5 .0 I (5.3 US qt .) M50 engine 6.5 I (6 .9 US qt .) M52 engine 6 .51 (6 .9 US qt .) S50US engine 6 .51 (6 .9 US qt .) S52US engine 6 .0 I (6 .3 US qt .) Manual transmission oil M42 engine 1 .1 I (1 .2 US qt .) M44 engine 1 .1 l(1 .2 US qt .) M50 engine 1 .1 1(1 .2 US qt .) M52 engine 1 .2 1(1 .3 US qt .) S50US engine 1 .2 1(1 .3 US qt .) S52US engine 1 .2 1(1 .3 US qt .)

Automatic Transmission Fluid

Specification

The automatic transmissions installed in the E36 modeis are normally filled with Dexron 111 automatic transmission fluid (ATF), although alternative fluids have been installed from the factory, depending on transmission type and model year . Some transmission are filled with a special BMW "life-time" automatic transmission fluid, whích does not require periodic fluid changes . Consult 240 Automatic Transmission for additional fluid specification information .

API service SH or

See 230 Manual Transmission for fluid specification information Continued

NOTEThe 1111 lubrican type can be found on ti ¡e `Yypeplate" on the side of the transmission. Consult an authorized BMW dealer for alternate fluid use and the most-up-to-date information regarding transmission operating fluids.

FLUID AND LUBRICANT SPECIFICATIONS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

MAINTENANCE PROGRAM

020-

Final Drive Gear Oil BMW recommends using only a specially formulated synthetic gear oil that is available through an authorized BMW dealer parts department. For additional information on this ¡ubricant and any other lubricants that may be compatible, contact an authorized BMW dealer senrice department. See 331 Final Drive.

Brake Fluid Brake fluid absorbs moisture easily, and moisture in the fluid affects brake performance and reliability. This is why brake fluid should be flushed from the system every two years. When replacing or adding brake fluid, use only new (luid from previously unopened containers . Do not use brake fluid that has been bled from the system, even if it is brand new. Use only DOT4 brake fluid. See 340 Brakes for more information .

Engine Coolant (Anti-freeze)

Fig. 3. Engine oil level dipstick location on 4-cylinder engine (arrow). Dipsfck is marked with mínimum and maximum level marks.

BMW recommends coolant that is a 50/50 mixture of distilled water and phosphate/nítrate free anti-freeze containing ethylene glycol . Anti-freeze raises the boiling point and lowers the freezing point of the coolant. It also contains additives that help prevent cooling system corrosion.

Power Steering Fluid The power steering fluid is Dexron II]® ATF, or equivalent . The system is permanently filled and does not have a drain. Routinely adding ATF is not required unless the system is leaking, WARNING Be sure to check the fluid specifications on the power steering reservoir to confirm the fluid type installed in the system. In some instances, the power steering system may be filled with an alternative hydraulic fluid designated CHF 7.1 .

Fig. 4. Oil filler cap (arrow). 6-cylinder engine shown.

0012202

ENGINE OIL SERVICE

Engine oil and fiiter, changing

Engine oii, checking leve¡

A complete oil change requires new oil (see Table e), a new oil filter insert kit, and a new drain plug sealing washer . The tools needed, a drain plug socket or box wrench (17 mm or 19 mm) and a drain pan (8-10 US qt . capacity), are described in 010 Fundamentals for the Do-It-Yourself Owner.

The engine oil leve] is checked with a dipstick in the engine block. Check the oii leve¡ with the canon a level surface, after the engine has been stopped for at least a few minutes. Check the leve¡ by pulling out the dipstick and wiping it clean. Reinsert it all the way and withdraw it again. The oil leve¡ is correct if it is between the two marks near the end of the stick. See Fig. 3. Add oil through the filler cap on the top of the cylinder head . See Fig. 4. Add only the amount needed to bring the oil leve¡ to the MAX mark on the dipstick, using an oil of the correct viscosity and grade. Too much oil can be just as harmful as too little .

NOTEIf using a "fast-lube" service facility for oil changes, make sure the technician hand-starts and torques the engine oil drain plug using hand-tools . Power tools can strip the threads of the plug and the oil pan.

ENGINE OIL SERVICE

020- 1 0

MAINTENANCE PROGRAM

1 . Run engine for a few minutes to warm engine oil. Shut engine off. 2. With car on level ground, place drain pan under oil drain plug . See Fig. 5.

5. When oil flow has diminished to an occasional drip, reinstall drain plug with a new metal sealing washer and torque plug . Tightening Torques " Engine oil drain plug M12 bolt (17mm wrench) . . . . . . . . 25 Nm (18 ft-Ib) M22 bolt (19mm.wrench) . . . . . . . . 60 Nm (44 ft-Ib)

6. Lubricate and install new O-rings. Install a new filter cartridge and housing cover. Tighten cover. See Fig. 7.

Fig. 5. Engine oil drain plug (arrow) in oil pan.

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iII~IIIi~ .

3. Remove filter housing cover. Remove filter cartridge and discard any O-rings. See Fig. 6.

Fig. 7. Oil flter housing on 6-cylínder engine. 4-cylinder engine is similar. Tightening Torque " Engine oil filter cover to oil filter housing . . . . . . . . . . . . . . . . . . . 25 Nm (18 ft-Ib)

0012460

7. Refill crankcase with oil.'Approximate oil capacity is listed in Table e. Use dipstick to check correct oil level.

Fig. 6. Engine oil filter cartridge. Note O-ring locations when removing cover and filter.

8. Start engine and check that oil pressure warning light immediately goes out.

4. Using a socket or box wrench, loosen drain plug at oil drain pan. By hand, remove plug and let oil drain into pan.

9. Allow engine to run for a few minutes to círculate new oil, then check for leaks at drain plug and oil filter. Stop engine and reclieck oil level.

CAUTIONPulí the loose plug away from the hole quickly to avoid being bumed by hot oil. It wíll run out quickly when the plug ís removed. If possible, use gloves to protect your hands.

ENGINE COMPARTMENT MAINTENANCE

ENGINE COMPAR

ENT MAINTENANCE

The information underthis heading describes routine maintenance-other than oil change-done in the engine compartment . It is not necessary for the car to be raised and supported off the ground . Information on oil change is given earlier under Engine Oil Change .

MAINTENANCE PROGRAM

020- 1 1

Air filter, replacing

Spark plugs, replacing

The specified maintenance intervals for the air filter are based on normal use. If the car is operated primarily in dusty conditions, the air filter should be serviced more frequently .

To access the spark plugs on 4-cylinder engines, remove the cover from atop the spark plugs. See Fig. 10. Using the special spark plug wire removal tool (attached to rear of cylinder head beneath engine cover), gently pull the spark plug wire from the spark plug . See Fig. 11 . Blow away any dirt from around the base of the plug to prevent it from entering the engine . Remove and install the spark plugsone at a time .

To replace the air filter on 6-cylinder engines, unclip and sude the filter cartridge assembly out of the air box and remove the filter from the frame assembly. See Fig. 8.

NOTESpark plug applications are often updated and superseded from the original plug specification . Consuff an authorized BMW parts department for the latest parts _' information. The spark plug fisted in the owners manual may not be the latest recommend spark plug, espgp cially on older cars.

0012625

Fig. 8. To remove airfilter cartridge on 6-cylinder engines, release filter cartridge at sides (arrows) and then remove filter element insert from cartridge. To replace the air filter element on 4-cylinder engines, separate the upper air filter housing section from the lowersection by unfastening the spring clips . Remove the air filter element from the air filter housing. See Fig. 9. Wipe the inside of the air filter housing clean and install the new element. Reinstall the upper air filter housing, making sure that the two halves are mated correctly. Refasten the spring-clips.

Fig. 10. To remove engine cover above spark piugs on 4-cylinder engine, turn retainers 90° counterclockwise and lift cover off.

Fig. 9. Air filter element being removed on 4-cylinder engine .

Fig. 11 . To remove spark plug wire from spark plug on 4-cylinder engine, sude special removal tool over spark plug wire end (arrow) and pull straight off. Use a screwdriver for added leverage . Special tool is stored at rear of cylinder head below top cover.

0012631

0012630

ENGINE COMPARTMENT MAINTENANCE

020-1 2

MAINTENANCE PROGRAM

6-cylinder engines use a coil-on-plug configuration, and removal of the top engine cover (between the camshafts) and ignition cofs are necessary. See Fig. 12 . Blow away any dust or dirt around the ignition coils, and then remove the coils. Blow away anydust or dirt around the spark plugs. Remove the spark plugs.

Battery cables should be tight. The terminals, the cable clamps, and the battery case should be free of thewhite deposits that indicate corrosion and acid salts. Even a thin ¡ayer of dust containing conductive acid salts can cause battery discharge. To remove battery corrosion, begin by disconnecting the cables . Disconnect the negative (-) cable first. Clean the terminal posts and the cable clamps with a wire brush. Clean the main chassis ground terminal next to the battery. Corrosion can be washed away with a baking soda and water solution that will neutralize the acid . Apply the solution carefully, though, since ít will also neutralize the acid inside the battery. Reconnect the cable clamps, positive (+) cable first. Lightly coat the outside of the terminals, hold down screws, and clamps with petroleum jelly, grease, or a commercial batteryterminal corrosion inhibitor. WARNING " Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii.

B11004

Fig. 12 . Ignition coil being removed from spark plug on M52 engine. NOTEIf necessary, see 120 Ignition System for more details on coil removal.

Lightly lubricate the new spark plug threads with a small amount of anti-seize compound . Thread the plugs into the cylinder head by hand to prevent cross-threading. Tightening Torque " Spark plug to cylinder head . . . . . . . 25 Nm (18 ft-ib)

Idie Speed Engine ¡dle speed can change due to a number of factors, including normal wear . The idle speed is electronically adaptive and non-adjustable . See 130 Fuel Injection for more information .

Battery, checking and cleaning The battery is located in the right side of the luggage compartment . Simple maintenance of the battery and its terminal connections will ensure maximum starting performance, especially in winter when colder temperatures reduce battery power. NOTEDesign characteristics of the convertible body cause vibrations in the trunk area . Therefore, E36 convertibles require a special battery designed for constant vibration . When repiacing the battery, be sure the replacement is designed specffically for the convertible.

ENGINE COMPARTMENT MAINTENANCE

" Battery acid is extremely dangerous. Take care to keep it from contacting eyes, skin, or clothing. Wear eye protection . Extinguish all smoking materials and do not work near any oyen flames .

Battery electrolyte should be maintained at the correct level just above the battery plates and their separators . The correct leve¡ is approximately 5 mm (1/4 in .) above the top of battery plates or to the top of the indicator marks (if applicable) . The battery plates and the indicator marks can be seen once the filler caps are removed. If the electrolyte level is low, replenish it by adding distilled water only.

Battery, repiacing Batteries are rated by ampere hours (Ah), the number of hours a specific current draín can be sustained before complete discharge, or by cold cranking amps (CCA), the number of amps available to crank the engine in cold weather conditions . In general, replacement batteries should always be rated equal or higher than the original battery. CAUTIONPrior to disconnecting the battery, read the battery disconnection cautions given at the front of thls manual on page viii.

The battery is held in place by a single hand screw and píate . A secure battery hold-down is important in order to prevent vibrations and road shock from damaging the battery. NOTE" Always disconnect the negative () cable first, and connect ft last While changing batteries, clean away any corrosion in or around the battery tray. " Design characteristics of the convertible body cause vibrations to oscillate in the trunk area . Therefore, the convertible model uses a special battery designed for this constant vibration .

MAINTENANCE PROGRAM Accelerator and Throttle Linkage The accelerator and throttie linkage should be lubricated periodically . Use a general purpose oil on the joints and bearings of the linkage. Use a multipurpose grease on the bearing points of the throttie plate.

Engine Drive Belts Drive belts and pulleys transfer powerfrom the engine crankshaft to various accessories . See Fig. 13 . Depending on model and model year, engine driven accessories are driven by Vbelts, poly-ribbed (serpentine) belts, or a combination of the two. For example, early4-cylinder engines, use two V-belts and one poly-ribbed belt . Inspect drive belts with the engine off. lf the belt shows signs of wear, cracking, glazing, or missing sections, it should be replaced immediately.

020- 1 3

NOTE" For the most accurate check, V-belt tension should be checked using a V-belt tension gauge. " Belt squealing is normally caused by loose belt tension. Belt dressings should not be used.

Tightening Torques " Tensioning gear (alternator belt tensioning) . . . . . . . . . . . . . . . . . . 7 Nm (62 in-lb) " Tensioning gear (power steering belt tensioning) . . . . . . . . 8 to 8.5 Nm (71 to 75 in-lb) " Tensioning gear locking nut . . . . . . . 24 Nm (18 ft-Ib)

NOTEWhen belts are replaced with new ones, store the old set in the luggage compartment for emergency use .

When installing a new belt, gently pry it over the pulleys. Too much force may damage the belt or the accessory. Tension the belt(s), run the engine for a few minutes (at least 1500 rpm), then recheck the belt tension. CAUTIONDo not over tighten the V-belts. Overtightening will cause shaft bearings to fail prematurely.

0012472

Poly-ribbed belt, replacing (4-cylinder engines buiit from 1194 and all 6-cylinder engines)

Fig. 13 . Drive belt and tensioner assembly for late 4-cylinder engine wíth poly-ribbed drive belt .

An automatic belt tensioner is used to keep the belts tensioned properly . Unless the tensioner mechanism malfunctions, the poly-ribbed belts do not require tension adjustment .

Vbelt, replacing (4-cylinder engines built up to 1194)

To reduce the chance of belt failure while driving, replacement of the belts every four years is recommended. Mark drive belt rotation directíon if removing and reusing an old belt.

V-belts should be inspected during regular maintenance intervais. Incorrect tension can decrease the life of the belt and the component it drives . The V-belt tension is adjusted through a toothed-rack mechanism.

To remove the belt, it is necessary to retract the self-tensioner. Using a breaker bar or other long socket assembly, rotate the tensionerto loosen the belt. See Fig. 14 or Fig . 15 . On 4-cylinder engines, it will be necessary to remove the A/C compressor belt to remove the main drive belt .

Inspect belts with the engine off. Twist the belt to inspect its sidewalls and bottom . Belt structural damage, glazed or shiny sidewaljs caused by a loose belt, or separation are al¡ reasons to replace a belt . Replacement of the V-belts every four years is recommended . Loosen the mounting bolts and adjust the belt-driven unit untilthe belt tension is as loose as possible . Remove the belt by slipping it over the pulleys. In some cases it may be necessary to remove one V-belt to getto another. Use a torque wrench and a crowfoot wrench to turn the tensioning gear bolt and set belt tension. Hold the wrench steady and tighten the locknut on the rear of the tensioning gear bolt . Tighten al¡ other mounting nuts .

WARNING Observe care when replacing the belt. Personal injury could result if the tensioner springs back into position uncontrollably.

With the belt removed from the pulleys, inspect the pulleys for wear or damage that may cause earlyfailure of the newbelt. This is also a good opportunity to inspect the belt-driven accessories, checking for bearing wear and excess play . Drive belt routing is shown in Fig. 16 and Fig. 17 . ENGINE COMPARTMENT MAINTENANCE

020- 1 4

MAINTENANCE PROGRAM

'92 irá

Alternator belt Coolant~ 0 pp o0o

Belt tensioner

uu11989

Fig . 14. Engine drive belt tensíoner being released on late 4-cylinder engine . Pry off tensioner cover and then lever tensioner in clockwise direction (as facing engine) and slip belt off pulleys .

0013000

Fig . 17. Engine drive belt routing for late 4-cylinder engine with polyribbed drive belts .

Cooling System Service Cooling system maintenance consists of maíntaining the coolant leve¡, inspecting hoses . Because the coolant's anti-corrosion and anti-freeze additives gradually lose their effectiveness, replacement of the coolant every two years up to 1996 models, and every three years from 1996 is recommended . As a preventive measure, replacement of the cooling system hoses every four years is also recommended .

B11177

Fig . 15 . Engine drive belt tensioner being released on 6-cylinder engine . Pry off tensioner cover and then lever tensioner in clockwise direction (as facing engine) and slip belt off pulleys .

o '~ I

CA UTIONUse only BMW approved phosphate-free antifreeze when filling the cooling system. Use of antifreeze containing phosphates !s considerad to be harmful to the cooling system . A translucent expansion tank, or overflow resenroir, provides monitóring of coolant leve¡ . Because the expansion tank is translucent, the coolant level can be checked visually without opening the system . Always check the coolant leve¡ with the engine cold . The coolant leve¡ should be at the maximum mark on the expansion tank, as shown in Fig . 18 . Hose connectionhld s soueg b tiht an d dry . Coolánt seepage indicates either that the hose clamp is loose, that the pose is damaged, or that the connection is dirty or corroded . Dried coolant has a chalky appearance . Hoses should be firm and springy. Replace any hose that is cracked, that has become soft and limp, or has been contaminated by oil . See Fig . 19.

Power steering fluid, checking leve¡ 0012470

Fig . 16 . Engine drive belt routing for 6-cylinder engine . A/C compressor drive belt not shown .

ENGINE COMPARTMENT MAINTENANCE

Check the power steering fluid level in the fluid reservoir . Park the car on leve¡ ground with the engine off. The level is correct if it is between the MIN and MAX marks on the dipstick . See Fig . 20 . If the leve¡ is below the MIN mark, start the engine and add fluid to the reservoir to bríng the leve¡ up . Stop the engine and recheck the leve¡ . Hand-tighten the reservoir cap .

MAINTENANCE PROGRAM

020- 1 5

Fig . 20 . Power steering fluid dipstick showing MIN and MAX marks. Fig . 18 . Fill mark on coolant expansion tank . Coolant level should be at mark when engine ís cold .

. .

. .- .

Ozone Damaged Hose 0012476

Fig . 19 . Examples of damage to coolant hoses . Any of conditions shown is cause for replacement . Courtesy of Gates Rubber Company, Inc .

Specification

OBD II enhanced emission standards require the engine control module (ECM) to monitor the oxygen content in the exhaust both before and after the catalytic converter . This allows for tighter control of the tail pipe emissions and also allows the ECM to diagnose converter problems . lf the DME detects that catalytic converter or oxygen sensor efficiency has degraded past a certain pre-programmed limit, it will turn on the Check Engine light, and store a diagnostic trouble code (DTC) in the ECM . Replacement of oxygen sensors at the specified intervals ensures that the engine and emission control system wíll continue to operate as designed . Extending the replacement interval may void the emission control warranty coverage . See 180 Exhaust System for information on replacing the oxygen sensors.

Tightening Torque " Oxygen sensor to exhaust system . . . . . . . . . . . . . 55±5 Nm (40±4 ft-Ib)

" Power steering fluid . . . . . . . . . . . . . . Dexron III®ATF

Oxygen Sensors 1996 and later engines are equipped with multiple oxygen sensors . See Fig . 21 . A regulating sensor is mounted before each catalytic converter and a monitoring sensor downstream of each converter. The regulating sensor monitors engine combustion efficiency and helps to control the fuel injection system and exhaust emissions . The monitoring sensor is used by the On-board diagnostic system to monitor the function of the catalytic converter .

NOTE5pecial sockets for replacing the oxygen sensor are available from most automotive parts stores. The socket has a groove cut down one side to allow the sensor to be installed without damaging the wire hamess.

ENGINE COMPARTMENT MAINTENANCE

020- 1 6

MAINTENANCE PROGRAM Oxygen sensor (regulating) \ Catalytic convertor

Oxygen sensor (monitoring) Exhaust flap actuator

Catálytic convertor

\ Oxygen sensor (monitoring)

Fig. 21 . Typical 1996 and later exhaust system showing oxygen sensor locations.

UNDER-CAR MAINTENANCE

NOTEDrain the fuel filter trom the inlet side into a container and inspect the drained fuel. Check for rust, moisture and contamination .

Fuel filter, replacing On early 4-cylínder cars, the fuel filter is mounted under the car on the left front bulkhead . On early 6-cylínder cars, the fuel filter is mounted to the front left motor mount in the engine compartment. See Fig. 22 .

0012726

Fig. 23 . Fuel filter location under center of car (arrow). Filter for M52 engine shown. When replacing the fuel filter, disconnect the battery negative (-) cable and clamp the filter inlet and outlet hoses to lessen fuel spillage . Loosen the center clamping bracket and the two hose clamps on either end of the filter. Note the arrow or markings indicating direction of flow on the new filter. Install the filter and use new hose clamps .

0013139

Fig. 22 . Fuel filter location (arrow) on bulkhead under left side of vehicle. Filter for M42 engine shown. On later cars, the fuel filter is located beneath the center of the car, approximately under the driver's seat . See Fig. 23 . A protective cover is installed overthe fuel filter, which must be removed to access the filter.

WARNING Fuel will be expelled when the filter is removed. Do not smoke or work near heaters or'other fire hazards . Keep a tire extinguisher handy. CAUTIONClean thoroughly around the filter connections before removing them.

UNDER-CAR MAINTENANCE

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

MAINTENANCE PROGRAM

020- 1 7

Tires, checking inflation pressure

Brake pad/rotor wear, checking

Correct tire pressures are important to handling and stability, fuel economy, and tire wear . Tire pressures change with temperature. Pressures should be checked often during seasonal temperature changes. Correct inflation pressures can be found on the driver's door pillar and in the owner's manual . Note that tire pressures should be higher when the car is more heavily loaded .

Al¡ E36 cars arefitted with disc brakes at al¡ four wheels. See Fig. 24 . Although the brakes are equipped with a brake pad warning system, the system only monitors one wheel per axle. It is recommended that pad thickness should be checked whenever the wheels are off or brake work is beggg done .

WARNING Do not inflate any tire to a higher pressure than the tiress maximum ínflation pressure listed on the sidewall. Use cara when addlng air to warm tires. Warm tire pressures can increase as much as 4 psi (0 .3 bar) over their cold pressures.

Tires, rotating BMW does not recommend tire rotation . Due to the cars suspension design, the front tires begin to wear first at the outer shoulder and the rear tires begin to wear first at the middle of the tread or inner shoulder . Rotating the tires may adversely affect road handling and tire grip . NOTEThe main purpose of tire rotation is to promote even wear and maximum tire life. Tire life may be decreased slightly if the tires are not rotated.

Wheels, aligning BMW recommends checking the front and rear alignment once a year and whenever new tires are installed. See 320 Steering and Wheel Alignment for a more detailed discussion of alignment requirements and specifications .

Brake system, inspecting Routine maintenance of the brake system includes maintaining the brake fluid in the reservoir, checking brake pads for wear, checking hand brake functíon, and inspecting the system for fluid leaks or other damage . Check that brake hoses are correctly routed to avoid chafing or kinkíng. Inspect unions and brake calipers for signs of fluid leaks. Inspect rigid fines for corrosion, dents, or other damage . Inspect flexible hoses for cracking . Replace faulty hoses or lines as described in 340 Brakes . WARNING Incorrect installation or overtightening hoses, fines, and unions may cause chafing or leakage . This can lead to partíal or complete brake system failure.

B323

Fig. 24 . Disc brake pad wear can checked through opening in caliper. The brake caliper should be unbolted from the suspension strut to properly inspect the brake pads and the rotors . See Fig. 25 . Brake caliper removal and installation procedures are given in 340 Brakes . Brake Pad Lining Minimum Thickness (Dimension A) " Front and rear disc brake pads . . . . 3.0 mm (0 .12 in)

Brake fluid, replacing BMW strictly recommends replacing the brake fluid every two years. This will help protect against corrosion and the effects of moisture in the (luid. See 340 Brakes for brake fluid flushing procedures .

Parking brake, checking The parking brake system is independent of the main braking system and may require periodic adjustment depending on use. Adjust the parking brake if the brake lever can be pulled up more than 8 clicks . Check that the cable moves freely . A description of the parking brake and parking brake adjustment can be found in 340 Brakes .

UNDER-CAR MAINTENANCE

020- 1 8

MAINTENANCE PROGRAM Manual transmission fluid, checking and filling The manual transmission fluid leve¡ should be checked at specified intervals. Check and fill the transmission with the car on a leve¡ surface. Transmission (luid leve¡ checking and replacement procedures are covered in 230 Manual Transmission .

Automatic Transmission Service The automatic transmission is not equipped with a dipstíck . Therefore, checking the ATF level is an ínvolved procedure, which includes measuring and maintaining a specified ATF temperature during the checking procedure. 0011920

Fig. 25 . Inspect brake pads with the caliper removed. Minimum brake pad thickness shown by dimension (A). NOTEThe parking brake may lose some of its effectiveness if it is not used frequently. This is due to corrosion buildup on the parking brake drum . To remove corrosion, apply the parking brake just until it begins to grip, then pulí the lever up one more stop (click) . Drive the car approximately 400 meters (1,300 ft.) and release the brake. To recheck the adjustment of the parking brake see 340

Brakes .

For more complete ATF service, including checking ATF leve¡ and ATF filter replacement procedures, see 240 Automatic Transmission .

Front suspension and steering linkages, inspecting Inspection of the front suspension'and steering includes a check of all moving parts for wear and excessive play . Also inspect the rubber seals and boots for cracks or tears that could allow the entry of dirt, water, and other contaminants . See 310 Front Suspension .

Exhaust system, inspecting

Rear suspension, inspecting

Exhaust system life varies widely according to driving habits and environmental conditions . If short-distance driving predominates, the moisture and condensation in the system will not fully dry out. This will lead to early corrosion damage and more frequent replacement .

Final drive and rear drive axle service consists of checking and changing the gear oil, inspecting for leaks, and checking the rear drive axle rubber boots fordamage .

Scheduled maintenance of the exhaust system is limited lo inspection . Check for restrictions due to dents or kinks. Check for weakness or perforation dueto rust . Checklo seethat all the hangers are in place and properly supporting the system and that the system does not strike the body . Alignment of the system and the location of the hangers are described in 180 Exhaust System .

Manual Transmission Service Manual transmission service consists of inspecting for leaks and checking and changing the fluid. Evidence of transmission leaks is fkely to be seen around the driveshaft mounting flange and at the bottom of the bellhousing . For more information on identifying oil leaks and their causes, see 230 Manual Transmission and 210 Clutch .

UNDER-CAR MAINTENANCE

The areas where leaks are most likely to occur are around the drive shaft and drive axle mounting flanges . For more infor mation on ídentifying oil leaks and their causes, see 330 Rear Suspension .

Final drive oil leve¡, checking Check the lubricant leve¡ with the car level. Remove the oil filler plug . The leve¡ is correct when the fluid just reaches the edge of the filler hole . Install and tighten the oil filler plug when the oil level is correct. See Fig. 26 . The final drive should be filled with a special BMW lubricant available through an authorized BMW dealer . In addition, the lubricant type varies depending on whether or nota limited-slip differential is fitted . Tightening Torque " Final drive filler plug to final drive housing . . . . . . . . . . . . . . . . . . 70 Nm (52 ft-Ib)

MAINTENANCE PROGRAM

020-19

Drive axie joint boots, inspecting The protective boots must be closely inspected for cracks and any other damage that will allow contaminants to get ínto the joint. If the rubber boots faf, the water and dirt that enter the joint will quickly damage ¡t . Replacement of the drive axle joint boots and inspection of the joints are described in 330 Rear Suspension .

BODY AND INTERIOR MAINTENANCE Windshield Wiper Biade Maintenance

0012474

NOTEUse a 14 mm or 17 mm alíen bit socket to remove the drain plug. " If the car is raised in the air, it should be leve¡.

Fuel tank and fuel fines, inspecting Inspect the fuel tank, fuel lines, and fuel system for damage or leaks. Check for fuel leaks in the engine compartment or fuel odors in the passenger compartment. Checkforfaulty fuel lines by bending them . If any leaks are present, fuel should be expelled . Check for any evaporative emissions hoses that may have become disconnected, checking carefully at the charcoal canister and evaporative emissions purge system . See 130 Fuel Injection and 160 Fuel Tank and Fuel Pump for component locations and additional information . WARNING When checking for fuel leaks, the engine must be cold. A hot exhaust manifold or exhaust system could cause the fuel to ignite or explode causing serious personal injury. Uentilate the work area and clean up spilled fuel immediately.

Clutch fluid, checking The hydraulic clutch and the brake system share the same reservoir and the same brake fluid. Clutch fluid leve¡ and brake fluid level are checked at the same time . See 340 Brakes for more information . See 210 Clutch for information on the clutch and the hydraulic clutch operating system .

Common problems with the windshield wipers include streaking or sheeting, water drops after wiping, and blade chatter. Streaking is usually caused when wiper blades are coated with road film or car wash wax. Clean the blades using soapy water. If cleaning the blades does not cure the problem then they should be replaced . BMW recommends replacing the wiper blades twice a year, before and afterthe cold season . Onolder cars, check the tension spring that holds the wiper to the glass. Replace the wiper arm if the springs are weak . Drops that remain behind afterwiping are caused by oil, road film, or diesel exhaust coating the windshield . Use an alcohol or ammonia solution, or a non-abrasive cleanser to clean the windshield . Wiper blade chatter may be caused by dirty or worn blades, by a dirty windshield, or by bent or twisted wiper arms . Clean the blades and windshield as described above. Adjust thewiper arm so that there is even pressure along the blade, and so that the blade is perpendicular to the windshield at rest . Lubricate the wiper linkage with a light oil. The linkage is located under the hood on the drivers side . If the problem persists, the blades are excessively aged or worn and should be replaced . See 611 Wipers and Washers.

Body and hinges, lubricating The door locks and lock cylinders can be lubricated with an oil that contains graphite . The body and door hinges, the hood latch, and the door check rods should be lubricated with SAE 30 or SAE 40 engine oil. Lubricate the seat runnerswith multipurpose grease . Do not apply any oil to rubber parts. If door weatherstrips are sticking, lubricate them with silicone spray or talcum powder. The hood release cable should be lubricated as well . The use of winter lock de-icersprays should be kept to an absolute minimum, as the alcohol in the de-icer will wash the grease out of the lock assemblies, and may cause the locks to corrode internally, or become difficult to operate.

ENGINE-GENERAL

100 Engine-General

100-1

020-20

MAINTENANCE PROGRAM

Seat Belts

Washing Chassis

Dirt and other abrasive particles will damage seat belt webbing . If ¡t is necessary to clean seat belts, use a mild soap solution . Bleach and other strong cleaning agents may weaken the belt webbing and should be avoided.

Periodic washing of the underside of the car, especially in winter, will help prevent accumulation of road salt and rust. The best time to wash the underside is just after the car has been driven in wet conditions . Spray the chassis with a powerful jet of water. Commercial or self-service car washes may not be best for this, as they may recycle the salt-contaminated water.

WARNINGDo not clean the seat belt webbing using dry cleaning or other chemicals. Allow wet belts to dry before allowing them to retract.

The condition of the belt webbing and the function of the retractor mechanisms should be inspected. See 720 Seat Belts for seat belt inspection information .

Exterior Washing The longer dirt is left on the paint, the greater the risk of damaging the glossy finish, either by scratching or by the chemical effect dirt particles may have on the painted surface. Do not wash the car in direct sunlight. If the engine hood is warm, allow it to cool . Beads of water not only leave spots when dried rapidly by the sun or heat from the engine, butalso can act as small magnifying glasses and burn spots into the finish . Wash the car with a mixture of lukewarm water and a car wash product. Rinse using plenty of clear water. Wipe the body dry with a soft cloth towel or chamois to prevent water-spotting.

Waxing For a long-lasting, protective, and glossy finish, apply a hard wax afterthe car has been washed and dried. Use carnauba or synthetic based products . Waxing is not needed after every washing. You can tell when waxing is required by looking at the finísh when it is wet. If the water coats the paint in smooth sheets instead of forming beads that rol¡ off, a new coat of wax is needed . Wax should not be applied to black trim pieces, rubber, or other plastic parts.

Speeial Cleaning Tar spots can be removed with a bug and tar remover. Never use gasoline, kerosene, nail polish remover, or other unsuitable solvents . Insect spots also respond to tar remover. A bit of baking soda dissolved in the wash water will facilitate their removal. This method can also be used to remove spotting from tree sap.

Interior Care Dirt spots can usually be removed with lukewarm soapy water or a dry foam cleaner. Use spot remover for grease and o¡I spots. Do not pour the (quid directly on the carpet or fabric, but dampen a clean cloth and rub carefully, starting at the edge of the spot and working inward . Do not use gasoline, naptha, or other flammable substances .

Leather Upholstery and Trim Leather upholstery and trim should be periodically cleaned using a slightly damp cotton or wool cloth. The idea is to get rid of the dirt in the creases and pores that can cause brittleness and premature aging. On heavily soiled areas, use a mild detergent (such as Woolite®) or other specially formulated leather r cleaners . Use two tablespoons to one quart of cold water. Dry the trim and upholstery completely using a soft cloth. Regular use of a good quality leather conditioner will reduce drying and cracking of the leather.

Polishing Use paint polish only if the finish assumes a dull lock after long service. Polish can be used to remove tar spots and tarnish, but afterwards a coat of wax should be applied to protect the clean finish . Do not use abrasive polish or cleaners on aluminum trim or accessories .

BODYAND INTERIOR MAINTENANCE

Cylinder Head and Valvetrain The aluminum cylinder head uses chain-driven double overhead camshafts and four valves per cylinder . See Fig. 1 . Tha rvfinriar hand nmnlnve n ernceflnier rineinn fnr nronter

1 . Camshafts 2 . Rocker arms 3 . Hydraulic valve adjusters (HVA) 4 . Valve and conical valve spring

ENGINE-GENERAL

100-1

100 Engine-General GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-1 Cylinder Block and Crankshaft . . . . . . . . . . . . 100-1 Connecting Rods and Pistons . . . . . . . . . . . . . 100-1 Cylinder Head and Valvetrain . . . . . . . . . . . . . 100-2 VANOS (Variable Valve Timing) . . . . . . . . . . . 100-2 DISA (Dual Resonance Intake System) . . . . . 100-3 Engine Management System . . . . . . . . . . . . . 100-3 Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-5 Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . 100-5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . 100-5 Lubrication System . . . . . . . . . . . . . . . . . . . . . 100-5

On-Board Diagnostics (OBD) . . . . . . . . . . . . . . 100-8

MECHANICAL TROUBLESHOOTING . . . . 100-5 Warnings and Cautions. . . . . . . . . . . . . . . . . . 100-5 Cylinder compression, checking . . . . . . . . . . . 100-6 Engine Mechanical Troubleshooting Table . . . 100-7

a . Engine Specifications . . . . . . . . . . . . . . . . . . . . . . .100-1 b . Engine Management Systems . . . . . . . . . . . . . . . . . 100-5 c . Engine Mechanical Troubleshooting . . . . . . . . . . . . 100-8 d . OBD 1 Fault (Blink) Codes (1992-1995 models only) . . . . . . . . . . . . . . . . . . . . .100-9 e . Engine Driveability Troubleshooting . . . . . . . . . . . .100-15

DRIVEABILITY TROUBLESHOOTING . . . 100-8

Basic Requirements . . . . . . . . . . . . . . . . . . . .100-11 Preventive Maintenance . . . . . . . . . . . . . . . . 100-11 Basic Engine Settings . . . . . . . . . . . . . . . . . . 100-11 Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . .100-11 Air Flow Measurement and Vacuum Leaks . .100-12 Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . 100-12 Wiring and Harness Connections . . . . . . . . . 100-13 Ground Connections . . . . . . . . . . . . . . . . . . . 100-13 Fue¡ Supply . . . . . . . . . . . . . . . . . . . . . . . . . .100-14 TABLES

GENERAL There are various engíne configurations used in the 19921998 E36 cars . See Table a.

Table a. Engine Specifications Model 318i/is/¡C 1992-1995 1996-1998 323ís/iC 1998 325i/is/iC 1992-1995 328i/is/iC 1996-1998 M3 1995 1996-1998

Engine code

No. of cyiinders

Dispiacement liters (cu . in .)

Compression ratio

Horsepower SAE net @ rpm

M42 M44

4 4

1 .8 (109 .6) 1 .9 (115 .6)

10 .0 :1 ~ 10 .0 :1

100 @ 6000 103 @ 6000

M52

2 .5 (152 .2)

10 .5 :1

168 @ 5,500

M50

2 .5 (152.2)

10 .0 :1

110 @ 5,900

M52

2 .8 (170 .4)

10.2 :1

190 @ 5,300

S50US S52US

6 6

3 .0 (182 .5) 3 .2 (192 .3)

10 .5 :1 10 .5 :1

240 @ 6,000 240 @ 6,000

Cylinder Block and Crankshaft

Connecting Rods and Pistons

On both four- and 6-cylinder engines, the cylinder block is cast ¡ron with integral cyiinders. The cyiinders are exposed on all sides to circulating coolant.

The forged connecting rods use replaceable split-shell bearings at the crankshaft end and solid bushings at the piston pin end . The pistons are of the three-ring type with two upper compression rings and a lower one-piece o¡i scraper ring . Fui¡-floating piston pins are retained with circlips .

The fully counterweighted crankshaft rotates in replaceable split-shell main bearings. Oiiways drilled into the crankshaft provide bearing lubrication . O¡I seals pressed into alloy sea¡ housings are installed at both ends of the crankshaft .

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

100-2

ENGINE-GENERAL

Cylinder Head and Valvetrain The aluminum cylinder head uses chain-driven double overhead camshafts and four valves per cylinder . See Fig. 1 . The cylinder head employs a crossflow design for greater power and efficiency . Intake air enters the combustion chamber from one side while exhaust gasses exit from the other. Oílways in the head provide lubrication for the camshafts) and valvetrain .

1 . Camshafts 2. Rocker arms 3. Hydraulic valve adjusters (HVA) 4. Valve and conical valve spring

Fig. 2. Cross section of M44 twin-cam, 4-valve-per-cylinder head . Note function of hydraulíc pedestal in combination with rocker arm (with roller bearing for reduced friction).

Fig. 1. M52 twin-cam, 4-valve-per-cylinder engine with hydraulíc lifters.

The main components of the VANOS system are the piston housing with integral spool valve and solenoid, and the modified intake camshaft and sprocket assembly . See Fig. 3.

On all engines except the M44 engine, valve clearance is by seif-adjusting hydraulic lifters. On M44 engines, instead of hydraulic lifters, hydraulic pedestais are used in combination with roller rocker arms to actuate the valves . Hydraulic pedestals have the same function as hydraulic lifters, which ís to maintain zero valve clearance, reduce valve noise, and elimínate routíne adjustment . See Fig. 2.

VANOS (Variable Valve Timing) 1993 and later 6-cylinder engines are equipped with a variable intake valve timing system, known as VANOS (from the German words Variable Nockenwellen Steuerung) . The VANOS system electro-hydraulically adjusts intake valve timing for enhanced mid-range performance. The VANOS system is controlled by the engine control module (ECM), using engine speed, engine load and engine temperature as the primary inputs . At low speeds, the intake valves open late to ensure smooth engine operation. At mid-range speeds, the valves open early (valve timing advanced, VANOS actuated) for increased torque, improved driveability, and reduced emissions. And at high speeds, the valves again open late for optimum power and performance.

GENERAL

B11001

Fig. 3. VANOS (variable intake valve timing) system used on M52 engine . When solenoid is actuated, oíl pressure is directed to front side of gear cup piston . This forces gear cup finto cam shaft to advance intake valve timing . When the engine is running, the piston housing is supplied with pressurized engine oil vía the solenoid-actuated spool valve. Depending on the position of the spool valve, oil is di rected to either the front or back side of the gear cup piston . When the solenoid is in the off position, engine oíl is directed to the back side of the piston . This holds the gear cup forward and valve timing is maintained at the normal "late" position . When the solenoid is energized, the spool valve is moved forward and oil pressure is directed to the front side of the piston . This in turn moves the gear cup further into the

ENGINE-GENERAL camshaft secondary drive, causing the camshaft to "advance" 12 .5°. The helical gears are cut so that forward motion of the gear cup is transiated into rotational motion of the camshaft . See 117 Camshaft Timing Chain for testing and repair information on the VANOS system .

DISA (Dual Resonance Intake System) DISA, used on 4-cylinder engines, is a dual intake runner system that effectively provides the advantages of both short and long intake runners within the same engine . For best performance, long intake runners are most beneficial at low- and mid-engine speeds (below 4,200 rpm), and short intake runners enhance torque at high engine speeds (above 4,200 rpm) . NOTEThe term DISA comes from the German words Differenzierte Sauganlage, andcan roughty be transiated as a differing intake manifold configuration .

The DISA system electro-pneumatically changes the intake runner length through the twin-section intake manifold and a change-over butterfly valve. The change-over valve is located at a point in the intake manifold where four pipes come into two. When the change-overvalve is closed, the 4-way primary intake manifold and the 2-way ram air manifold are connected to make the "long" configuration. When the change-overvalve opens, intake air flow is redirected through only the short 4way primary intake manifold . The change-overvalve is held in the normally open position by a spring . This allows for an open valve in the event of system failure. During low and mid engine speeds, the DME control module supplies power to the solenoid valve, which in turn allows vacuum to be applied lo the vacuum diaphragm. This causes the valve to close (long-pipe configuration) . When engine speed reaches approximately 4,800 rpm, the DME control module electrically signals the solenoid valve and the valve opens, creating the short pipe configuration: Further detafs on DISA can be found in 130 Fuel Injection.

The DISA solenoid valve is controlled by the DME control module, using engine speed as the primary input. The main components of the system are the modified twin-section intake manifold with change-over valve, the twin-barrel throttle body, and the electrical/pneumatic actuating components . See Fig. 4.

UpPer, in take -1 ? , manifold

Engine Management System Al¡ engines covered by this manual use an advanced engine management system called Digital Motor Electronics (DME). In the DME system, advanced On-Board Diagnostics (OBD), fuel injection, ignition, and otherfunctions, are combined under the control of the Engine Control Module (ECM). See Fig. 5.

q:lZU

- Lower intake manifold with butterfly va¡

DISA vacuum ' ~servo

Throttle housing (Heated)

Fig . 4 .

100-3

1-1

DISA system components . DISA changes the intake runner

length based on engine speed.

EíY1z

le -

DISA solenoid valve 0012591

GENERAL

100-4

ENGINE-GENERAL ECM RELAY CONTROL

TERMINAL 15 MEMORY POWER

FUEL PUMP RELAY CONTROL

AUX GROUND

I MAIN GROUND J_ -

ECM RELAY

AC COMPRESSOR RELAY CONTROL

OPERATING POWER CRANKSHAFT POSITION dESENSOR

SECONDARY AIR 1NJECTION AIR PUMP® RELAY CONTROL

CAMSHAFT POSITION SENSOR

PRE CAT

POST CAT

OXYGEN SENSOR HEATING #

THROTTLE POSITION ENGINE COOLANT TEMP

IDLE CONTROL VALVE

INTAKE AIR TEMP

MS41 .1

FUEL INJECTOR CONTROL (SEQUENTIAL)

IGNITION COILS CONTROL

FUEL INJECTION (TI) FUEL TANK PRESSURE SENSOR S-EML S-MSR

ASC

ENGINE SPEED (TD) Lr"Q if~ CIYVFIYC AMP CONTROL

CHE ENGINE

THROTTLE POSITION

S-ASC

VEHICLE SPEED

LOW FUEL LEVEL

E36 IHKA

A/C SWITCH ON (AC) COMPRESSOR"ON" SIGNAL (KO)

INDIVIDUAL SERIAL NUMBER

6 THROTTLE 1Q\\\ POTENTIOMETER POWER

. . : . . . . -11 CAN

TCM

SCAN (DES ER ;

DIAGNOSIS OBD II GENERIC SCAN TOOL

Fig. 5. Siemens MS 41 .1 OBD II engine management system used on 1996 and later M52 engines.

GENERAL

ASC

I II 0012596

ENGINE-GENERAL Various versions of DME systems are used on the cars covered by this manual . See Table b . Each system is highly adaptive to compensate for things such as engine wear and vacuum leaks .

Table b. Engine Management Systems Engine

1 System

4-cylinder engines M42 (1992-1995) M44 (1996-1998)

Bosch DME Ml .7 Bosch DME M5 .2 (OBD II)

6-cylinder engines M50 (1992) M50 VANOS (1993-1995) M52 (1996-1998) S50US (1995) S52US (1996-1998)

Bosch DME M3 .1 Bosch DME M3 .3 .1 Siemens MS41 .1 (OBD II) Bosch DME M3 .3 .1 Siemens MS41 .1 (OBD II)

ignition Both the 4-cylinder and 6-cylinder engines use a distributorless ignition system with individual ignition coils for each cylinder .

Fuel Delivery Pressurized fuel from the in-tank fuel pump is injected via solenoid-type fuel injectors . The ECM controls the opening and closing of the injectors by switching the ground side of each injector circuit . The exact amount of fuel injected is determined by the amount of time the injectors are open .

Cooling System Whenever the engine is running, a coolant pump circulates coolant through the engine and, if either heater control valves are open, through the heater core in the passenger compartment . The coolant absorbs excess heat and carries it to the radiator where it is transferred into the passing airstream . A thermostat controls the flow of coolant through the radiator based on engine temperature .

Lubrication System The lubrication system is pressurized whenever the engine is running . The oil pump draws oil through a pickup in the bottom of the oil pan, then forces it through a replaceable oil filter and finto the engine oíi passages . On 4-cylinder engines, the oil pump is mounted to the front engine cover . On 6-cylinder engines, the chain-driven oil pump is bolted to the bottom of the cylinder block . A pressure relief valve limits the maximum system pressure . A bypass valve prevents the oil filter from bursting and insures engine lubrication should the filter become plugged . See 119 Lubrication System for additional information .

100-5

MECHANICAL TROUBLESHOOTING When troubleshooting an engine that fails to start or runs poorly, first check its mechanical condition-particularly if the

engine has high mileage.

Warnings and Cautions For personal safety, as well as the protection of sensitive electronic components, the following warnings and cautions must be adhered to during all troubleshooting, maintenance, and repairwork. WARNING " The ignition system produces high voltages that can be fatal. Avoid contact with exposed terminals and use extreme caution when working on a car with the ignition switched on or the engine running. " Do not touch or disconnect any high voltage cables from the coil, distributor, or spark plugs while the engine is running or being cranked by the starter " Connect and disconnect the engine management system wiring and test equipment leads only when the ignition is switched off. " Gasoline is highly flammable and its vapors are explosive. Do not smoke or work on a car near heaters or other fire hazards when diagnosing and repairing fuel system problems . Have a fire extínguisher available in case of an emergency. " Disconnecting the battery may erase fault code(s) stored in control module memory. Using special BMW diagnosnnc equipment, check for fault codes prior to disconnecting the battery cables. If the Check Engine light is illuminated, see OnBoard Diagnostics (OBD) for fault code information. If any other system faults have been detected (indicated by an illuminated warning light), see an authorized BMW dealer. CAUTION" Prior to disconnecting the battery, read the battery disconnection cautions gíven at the front of this manual on page viii. " Do not connect any test equipment that delivers a 12-volt power supply to terminal 15 (+) of the ignition coil. The current flow may damage the ECM. In general, connect test equipment only as specified by BMW, this manual, or the equipment maker. " Do not disconnect the battery with the engine running. Do not run the engine with any of the spark plug wires disconnected.

MECHANICAL TROUBLESHOOTING

100-6

ENGINE-GENERAL

Cylinder compression, checking A compression tester is needed to make a compression test . To obtain accurate test results, the battery and starter must be capable of cranking the engine at 250-300 rpm, and the engine should be at normal operating temperature . Use compressed air to clean around the spark plugs before removal. 1 . Disable the ignítion system by removing the engine management system main relay and the fuel pump re¡ay. See Fig. 6. WARNING The ignítion system produces high voltages that can be fatal. Avoid contact with exposed termínals and use extreme caution when working on a car wíth the ignítion switched on or the engine running.

Fuel pump re ay

0012630

Fig. 7. Remove spark plug wires from spark plugs on 4-cylinder engine using special tool . Tool is stored under cover at rear of cylinder head (arrow) .

DM E main relay

o oa ooa ., o00 oao

0013034,

Fig. 6. Engine management relays in power distribution box in left rear of engine compartment . CAUTION" On OBD 11 cars, making a compression test may cause a fault to set in the ECM and may also illuminate the Check Engine light. The light can only be tumed out using special scan tool equipment, using eíther the BMW special servíce tool or using a "generic" OBD 11 scan tool. Disconnecting the battery will not erase the fault memory nor turn out the light. " Failure to remove the main relay or attempting to disable the ignítion system by other methods may result in damage to the engine control module.

2. On 4-cylinder engine : Remove plastic engine cover from top of cylinder head . Disconnect spark plug wires and remove spark plugs. See Fig. 7. 3. On 6-cylinder engine : Remove top engine cover by prying off nut covers and removing mounting nuts . See Fig. 8.

Fig. 8. Remove engine cover on 6-cylinder engine by prying off nut covers and removing nuts (A). Be careful not to let rubber insulators fall off as cover is removed (arrows) . 4. On 6-cylinder engines, disconnect the harness connectors from the ignítion coils by lifting the retaining clip . Remove the coil mounting nuts and remove the six coils. See Fig. 9. Remove the spark plugs. NOTEUsed spark plugs should be reinstalled in the same cylinder from which they were removed.

5. Insta¡¡ the compression gauge in the first cylinder's spark plug hole, tight enough to form a good seal .

MECHANICAL TROUBLESHOOTING

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ENGINE-GENERAL

1 :00-7

Compression Pressure " Minimum . . . . . . . . . . . . . . . . 10-11 bar (142-156 psi) " Maximum difference between cylinders . . . . . . . . . . . . . . . . 0.5 bar (7 psi) Reinstall the spark plugs and spark plug wires or ignition cofs . The remainderof installation is the reverse of removal. Be sure to reihstall al¡ wires disconnected during the test, especial¡y ground wires at the coils and cylinder head cover (where applicable).

eiioo4 Fig. 9. Remove ignition coils on 6-cylinder engine by disconnecting harness connector and removing mounting bolts (arrows) . 6. With the parking brake set, the transmission in Park or Neutral, and the accelerator pedal pressed to the floor, crank the engine with the starter. Record the highest value indicated by the gauge. NOTE" The compression gauge reading shoutd increase with each compression stroke and reach near its maximum reading in about 4-6 strokes. " All cylinders shoutd reach maximum compression in the same number of strokes. If a cylinder needs significantly more strokes to reach maximum compression, there is a problem.

Tightening Torque " Spark plug to cylinder head . . . . . . . 25 Nm (18 ft-Ib) Low compression indicates a poorly sealed combustion chamber. Relatively even pressuresthat are below specification normally indicate worn piston rings and/or cylinder walls. Erratic values tend to indicate valve leakage. Dramatic differences be tween cylinders are often the sign of a failed head gasket, bumed valve, or broken piston ring .

Engine Mechanical Troubleshooting Table Table c lists the symptoms of common engine mechanical problems, their probable causes and the suggested corrective actions. The bold type indicates the repair groups where applicable test and repair procedures can be found.

7. Release the pressure at the compression gauge valve, then remove the gauge from the spark plug hole . Repeat the test for each of the other cylinders and compare the results with the values given below .

MECHANICAL TROUBLESHOOTING

100-8

ENGINE-GENERAL Table c. Engine Mechanical Troubleshooting Symptom

1 . Engine will not start or run . Starter cranks engine at normal speed .

Probable cause and corrective action a . No fuel reaching engine. Check for fuel in tank . Fuel pump not operating . Repair Group 160 b . No spark . Check ignition system . Repair Group 120 c. Incorrect valve timing . Check timing chain . Repair Group 117

2. Check Engine warning light illuminated .

a. DME engine management system self-diagnostic fault detected . Sea an authorized BMW dealer or other qualified shop for OBD II fault code diagnosis . See also Onboard Diagnostics (OBD), given later in this repair group.

3. White exhaust smoke (steam) .

a. Failed cylinder head gasket (probably accompanied by low compression readings). Replace gasket and resurface cylinder head if necessary. Repair Group 113 b . Warped or cracked cylinder head . Resurface or replace cylinder head . Repair Group 113 c. Cracked cylinder block . Replace engine or short block .

4. Blue-gray exhaust smoke and oily spark plugs . Indicates oii burning in combustion .

a. Contaminated or gasoline-diluted engine oil . Change engine oil and replace oil filter. Repair Group 020 b . Faulty valve guide seals or valve guides . Replace valve guide oil seals or overhaul cylinder head . Repair Group 116 c. Worn piston rings . Overhaul or replace engine . d . Failed cylinder head gasket . Replace gasket . Repair Group 113

5. Pinging or rattling when under load, traveling uphill, or accelerating, especially from low speeds. Indicates pre-ignition or detonation .

a. Ignition timing too advanced . Ignition knock sensors faulty (Check Engine light illuminated) . Repair Group 120 b . Fuel octane leve¡ too low. c. Engine running too hot or overheating . Check cooling system . Repair Group 170 d . Air/fuel mixture too lean (Check Engine light illuminated) . Repair Group 130

6 . Light metallic tapping that varies directly with engine speed . Oil pressure warning light not illuminated .

a. Valve clearances excessive . Check hydraulic valve adjusters. Repair Group 116 b . Low oil pressure or possibly defective warning light circuit . Check oil pressure and warning light circuit . Repair Group 119 c. Dirty oil . Change oil . Repair Group 020 .

7. Light metallic knock that varies directly with engine speed . Oil pressure warning light blinking or fully illuminated ; may be most noticeable during hard stops or cornering .

a. Low oil leve¡ . Check and correct oil leve¡ . b . Low oil pressure/worn or faulty oil pump. Oil pump pickup restricted/clogged. Check oil pressure . Repair Group 119

8. Screeching or squealing under load that goes away when coasting .

a. Loose, worn, or damaged drive belt. Inspect belt(s) . Repair Group 020

9. Growling or rumbling that varies with engine rpm . Indicates a bad bearing or bushing in a n engine-driven accessory.

a. Remove drive belt(s) to identify faulty component. Check for play, bearing roughness, and loose mountings . Refer to appropriate repair group for repair procedures .

DRIVEABILITY TROUBLESHOOTING

On-Board Diagnostics (OBD)

On-Board Diagnostics is incorporated into al¡ engine management systems used on the cars covered by this manual . Therefore, checking for fault codes should be the first step in troubleshooting a driveability problem . For additional information on engine management and repair see 130 Fuel Injection .

Two generations of OBD are used on the cars covered by this manual :

DRIVEABILITY TROUBLESHOOTING

On-Board Diagnostics

" 1992-1995 models . . . . . . . . . . . . . . . . . . . . . OBD I " 1996-1998 models . . . . . . . . . . . . . . . . . . . . . OBD II The OBD system detects emissions-related engine management malfunctions and tucos on the Check Engíne light in the instrument cluster. The Check Engine light will stay on until the code(s) are called up and the memory is erased . When faulty are detected, the OBD system stores a Diagnostic Trouble Code (DTC) in the system ECM . In addition, the Check Engine warning light will come on if an emissions-related fault is detected .

ENGINE-GENERAL

100-9

2 .5 seconds, then go off for 2 .5 seconds . At this point, the fault codes will begin to flash . See Table d .

NOTE-

" On cars with OBD ti, specialized OBD 11 scan tool equipment must be used to access the DTCs, either using the BMW special tool ora `generic" OBD 11 scan tool. See 130 Fuel Injection .

If more than one fault has been detected, each code will be separated by a 2 .5 second pause . When al¡ fault codes have been displayed, there will be 0 .5 second flash and then the light will remain off . To read the codes again, turn the key off and then on again . Depress the accelerator pedal to the floor five times quickly (within 5 seconds) . The codes will begin to repeat.

" The 08D 11 fault memory (including an iiluminated Check Engine light) can only be reset using the special scan tool. Removing the connector from the ECM or disconnecting the battery will not erase the fault memory. On cars with OBD I, fault codes can be read by turning the ignition key on and fully depressing the accelerator pedal to the floor five times within five seconds . The Check Engine light will then remain on for five seconds, blink off, come on for

To erase the fault code memory, first make sure the fault code 1000 (short blink and then light goes out for long period) is present, then depress the throttle fully for at least 10 seconds. Read the fault codes as described earlier and check for the 1444 code (no faults stored) .

Table d. OBD 1 Fault (Blink) Codes (1992-1995 modeis only) Graphic representation of flashing Check Engine light fault code: 1221 5 Seconds . :-

2.5 ~-

--05-Fault code and meaning

-,-------------- Check Engine light on Check Engine light off

1 Corrective action

Code 1211 : DM E Control Module

DME control module may be faulty. This code appears if the control module fails the self test. Check inputs to control module . Repair Group 130

Code 1215 : Mass air flow sensor

Check air flow or mass air flow sensor and wiring to sensor. Repair Group 130

Code 1216: Throttle potentiometer

Test throttle potentiometer resistance and wiring . Repair Group 130

Code 1218 : Output stage, group #1 (DME 3 .3.ionly)

Test DME control module input/outputs . Repair Group 130

Code 1219 : Output stage, group #2 (DME 3 .3 .1 only)

Test DME control module input/outputs . Repair Group 130

Code 1221 : Oxygen sensor #1

Check sensor output signal to DME control module . Repair Group 130

Code 1222 : Oxygen sensor lean/rich control stop

Check for intake air leaks or reasons for rich míxture . See Driveability Troubleshooting given earlier in this repair group

Code 1223: Coolant temperature sensor (NTC) Code 1224: Air temperature sensor (NTC)

1 Test coolant temperature sensor. Repair Group 130 Test intake air temperature sensor. Repair Group 130

Code 1225: Knock sensor #1 (DME 3 .3.1 only)

1 Check knock sensor and sensor wiring . Repair Group 120

Code 1226 : Knock sensor #2 (DME 3 .3.1 only)

Check knock sensor and sensor wiring . Repair Group 120

Code 1231 : Battery voltage monitor

Test battery voltage and battery check charging system and starter. Repair Group 121

Code 1234 : Speedometer "A" signal (DME 3 .3 .1 only)

Check wiring between instrument cluster and DME control module . Electrical Wiring Diagrams

Code 1237 : A/C compressor cutoff (DME 3 .3 .1 only)

Test DME control module inputs/outputs from A/C system . Repair Group 130

Code 1242: A/C compressor signal (DME 3 .3 .1 only)

Test DME control module inputs/outputs from A/C system . Repair Group 130 DRIVEABILITY TROLIBLESHOOTING

100- 1 0

ENGINE-GENERAL Table d. OBD I Fault (Blink) Codes (continued) (1992-1995 modeis only)

Graphic representation of flashing Check Engine light fault code : 1221 -; 5 Seconds . ;--~ 2.5 r

---------------- Check Engine light on Check Engine light off

Fault code and meaning

Corrective action

Code 1243 : Crankshaft position sensor (DME 3 .3 .1 only)

Test crankshaft position/rpm sensor and wiring from sensor lo DME control module. Repair Group 120

Code 1244 : Camshaft position sensor (DME 3 .3 .1 only)

Test camshaft position sensor and wiring from sensor to DME control module . Repair Group 130

Code 1245 : Electronic transmission control intervention (DME 3 .3 .1 only)

Check wiring between DME control module and auto . transmission control module

Code 1247: Ignition secondary monitor (DME 3 .3 .1 only)

Check secondary voltage lo ignition coils . Check wiring at ignition coils. Repair Group 120

Code 1251 : Fuel injector #1 (DME 3 .113.3 .1 only)

1 Test injector operation/signal lo injector. Repair group 130

Code 1252: Fuel injector #2 (DME 3 .113.3 .1 only)

Test injector operation/signal lo injector. Repair group 130

Code 1253 : Fuel injector #3 (DME 3 .1/3.3 .1 only)

Test injector operation/signal to injector. Repair group 130

Code 1254 : Fuel injector #4 (DME 3 .1/3.3 .1 only)

Test injector operation/signal to injector. Repair group 130

Code 1255 : Fuel injector #5 (DME 3 .1/3.3 .1 only)

Test injector operation/signal to injector. Repair group 130

Code 1256 : Fuel injector #6 (DME 3 .1/3.3 .1 only)

Test injector operation/signal lo injector. Repair group 130

Code 1261 : Fuel pump control

Test fuel pump relay and fuel pump circuit . Repair group 160

Code 1262 : Idle speed control

Test idle air control valve and signal to valve . Repair Group 130

Code 1263 : Fuel tank evaporative (EVAP) system

Test EVAP purge valve . Repair Group 160

Code 1264 : Oxygen sensor heater

1 Test oxygen sensor heater and heater relay. Repair group 130

Code 1265 : Check engine lamp (DME 3 .3 .1 only)

1 Test for faulty bulb or wiring . Electrical Wiring Diagrams

Code 1266 : VANOS (DME 3 .3 .1 only)

1 Test VANOS solenoid. Check for signal to VANOS solenoid .

Code 1267 : Air pump relay control (DME 3 .3 .1 only)

Test air pump relay and wiring (where applicable) Electrical Wiring Diagrams

Code 1271 : Ignition coil #1 (DME 3 .3 .1 only)

Test ignition coil and wiring to ignition coil . Repair Group 120

Code 1272 : Ignition coil #2 (DME 3 .3 .1 only)

Test ignition coil and wiring lo ignition coil . Repair Group 120

Code 1273 : Ignition coil #3 (DME 3 .3 .1 only)

Test ignition coil and wiring lo ignition coil . Repair Group 120

Code 1274 : Ignítion coil #4 (DME 3 .3 .1 only)

Test ignition coil and wiring to ignition coil . Repair Group 120

Code 1275 : Ignition coil #5 (DME 3 .3 .1 only)

Test ignition coil and wiring lo ignition coil . Repair Group 120

Code 1276: Ignition coil #6 (DME 3 .3 .1 only)

Test ignition coil and wiring lo ignition coil . Repair Group 120

Code 1281 : DME control module memory supply (DME 3 .3.1 only)

Check voltage supply from battery lo DME control module. Electrical Wiring Diagrams

Code 1282 : Fault code memory (DME 3 .3 .1 only)

Check DME control module inputs/outputs . Control module may be faulty. Repair Group 130

Code 1283: Fuel injector output stage (DME 3 .3 .1 only)

Check DME control module inputs/outputs . Control module may be faulty. Repair Group 130

DRIVEABILITY TROUBLESHOOTING

ENGINE-GENERAL

100- 1 1

Table d. OBD I Fault (Blink) Codes (continued) (1992-1995 models only) Graphic representation of flashing Check Engine light fault code : 1221 -; 5 Seconds. ~-

2.5 ;-

7-1-------------- Check Engine light on Check Engine light off

Fault code and meaning

Corrective action

Code 1286 : Knock control test pulse (DME 3 .3 .1 only)

Check DME control module inputs/outputs. Control module may be faulty Repair Group 130

Code 1000 (light remains off) :

End of fault code output-all fault codes have been displayed. No ~ corrective action necessary. Repeat test if necessary No more faults . No corrective action necessary. This code must be present lo erase fault memory

Code 1444:

Basic Requirements

Preventive Maintenance

The following list contains basic checks that should be made when experiencing driveability problems .

The condition of the fuel, ignition and emission control system components has a direct effect on engine performance and driveability. BMW specifies maintenance of certain parts at regular intervals lo keep the engine in proper tune . Extending maintenance intervals beyond the time or mileage recommended by the manufacturer can adversely affect the waythe engine runs . When troubleshooting driveability problems, a good starting point is to perform a major engine service, particularly if one is overdue. For maintenance schedules, major engine service and other driveability-related maintenance procedures, see 020 Maintenance Program .

1 . Check intake (induction) system for leaks. Check for cracked, loose, or disconnected hoses and duct work . Check that all hose clamps are tight. NOTEAn air leak allows unmeasured air to enter the engine, offen resulting in an in overly lean fuel mixture and causing driveability problems which will cause the Check Engine light to come on .

2. Check that the battery is in good condition. Check that the cables are tight and free of corrosion at both ends . Check that all related ground points are firmly connected and in good condition. Check al¡ harness connectors for damage and corrosion . 3. Check for prwer and ground at the Engine Control Module (ECM). Check the main grounds for the ECM. See 130 Fuel Injection. 4. Check the fuses. Check for sufficient fuel in the tank . If the engine ran out of fuel, it will take a little time to restore fuel pressure . See 160 Fuel Tank and Fuel Pump . 5. Check for spark at the spark plugs. If the tachometer needle bounces while the engine is cranked by the starter then the ignition system is probably working correctly. See 120 Ignition System . 6. Check for any faults through the On-Board Diagnostics system . See On-Board Diagnostics (OBD).

Basic Engine Settings Idle speed, idle mixture (%CO), and ignition timing are not adjustable . The adaptive engine management system is designed lo automatically compensate for changes in engine operating conditions, although the adaptive range is limited. Once these limits are exceeded, driveability problems usually become noticeable . NOTEIf the DME adaptive limits are exceeded, the Check Engine light will come on, indicating an emission related fault. See 130 Fuel Injection,

Oxygen Sensors A high oxygen level in the engine exhaust indicates a lean air-fuel mixture and a low oxygen level indicates a rich mix ture . The oxygen sensor, shown in Fig. 10, measures the oxygen content in the exhaust gas and generates a variable voltage signal . Using that feedback signal as an input, the DME control module fine tunes the air-fuel mixture. DRIVEABILITY TROUBLESHOOTING

100-1 2

ENGINE-GENERAL

NOTEThe oxygen sensor signal is ignored until the engine reaches a specified minimum temperature . Therefore, when troubleshooting cold engine driveability problems, the oxygen sensor can be ruled out as a possible cause.

As the oxygen sensor ages, its ability to react quickly to changing conditions deteriorates, and it may eventually cease to produce any signal at all. To check the operation of the oxygen sensor, see 130 Fuel Injection: NOTEOn 1996 and later cars, OBD 11 enhanced emission standards require the engine control module (ECM) to monitor the oxygen content in the exhaust both before and after the catalytic converter. This allows for tighter control of the tail pipe emissions and also allows the ECM to diagnose converter problems. If the DME detects that catalytic converter or oxygen sensor efficiency has degraded past a certain pre-programmed limit, it will turn on the Check Engine light, and store a diagnostic trouble code (DTC) in the ECM.

Catalytic

B9506

Fig. 10 . Regulating oxygen sensor measures oxygen content of exhausY gas as indicator of .¡_fi .1 ratio and "-k,. E- efficiency. Monitoríng oxygen sensor (not shown) monitors catalytic converter operation. Replacement of oxygen sensors at the specified intenrals ensures that the engine and emission control system wili continue to operate as designed . As the oxygen sensor ages, its ability to react quickly to changing conditions deteriorates, and it may eventually cease to produce any signal at all . As the oxygen sensor ages, its ability to react quickly to changing conditions deteriorates, and it may eventually cease to produce any signal at all. To check the operation of the oxygen sensor, see 130 Fuel Injection.

DRIVEABILITY TROUBLESHOOTING

Air Flow Measurement and Vacuum Leaks The primary input used by the fuel injection system to determine how much fuel should be delivered is the signal from the mass air flow sensor in the intake air ductwork. Because proper fuel metering depends on accurate measurement of the incoming air, any unmeasured air that enters the engine downstream of the mass air flow sensor will cause a lean air-fuel mixture and possibly affect driveability. NOTEIf a large air leak is causing driveability problems, the Check Engine light will usually be illuminated and a fault will be stored in the fault code memory. See On

Board Diagnostics (OBD).

There are many places for unmeasured air to enter the engine . First, inspect all hoses, fittings, ducts, seals, and gaskets in the intake air tract for cracks or looseness. It may be necessary to remove parts that cannot be fully checked in their installed positions. Also make sure all of the intake manifold and throttle body mounting nuts are tight. In addition to air leaks, air restrictions can also cause driveability problems . Remove the air filter and hold it up to a strong light source . If the filter does not pass light, it is restricted and should be replaced . Also, remove the intake air ductwork and check for oily deposits at the throttle plate. Buildup in this area can cause an erratic idle . Clean away any deposits using a cloth wetted with carburetor cleaner and reinstall the ductwork. CAUTIONDo not spray carburetor cleaner directly in the throttle anea. Spraying cleaner may force it into the throttle position switch or sensor and cause damage.

gattery Voltage All of the electrical components in the fuel injection and ignition systems require a minimum voltage to operate properly . When troubleshooting engine driveability problems, one of the first checks should be to make sure the battery is fully charged and capable of delivering all its powerto the electrical system . To make a quick check of battery charge, measure the voltage across the battery terminals with all cables attached and the ignition off. A fully charged battery will measure 12 .6 volts or slightly more, compared to 12 .15 volts for a battery with a 25% charge . Even a fully charged battery cannot deliver power unless it is properly connected to the electrical system . Check the battery terminals for corrosion and loose cable connections . If the battery does not maintain the proper voltage, the charging system may be at fault. See 121 Battery, Starter, Alternator .

ENGINE-GENERAL

100- 1 3

If a battery cable connection has no visible faults, but is still suspect, measure the voltage drop across the connection . A large drop indicates excessive resistance, meaning the connection is corroded, dirty, or damaged. Clean or repair the connection and retest . NOTEFor instructions on conducting a voltage drop test, and other general electrical troubleshooting information, see 600 Electrical System-General .

Wiring and Harness Connections The electronic fuel injection and ignition systems operate at low voltage and current values, making them sensitive to small increases in resistance . The electrical system is routinely subjected to corrosion, vibration and wear, so faults or corrosion in the wiring harness and connectors are common causes of driveability problems . Visually inspect all wiring, connectors, switches and fuses in the system . Loose or damaged connectors can cause intermittent problems, especially the small terminals in the ECM connectors . Disconnect the wiring harness connectors to check for corrosion; and use electrical cleaning spray to remove contaminants . Often, simply disconnecting and reconnecting a dirty connector several times will clean the terminals and help to reestablish good electrical contact.

UU,~uyi

Fig. 11 . Main ground (arrow) for engine management system . Grounds are in right rear of engine compartment .

If a wiring harness connector has no visible faults, but is still suspect, measure the voltage drop across the connector. A large drop indicates excessive resistance, meaning the connector is corroded, dirty or damaged. Clean or repair the connector and retest .

Ground Connections For any electrical circuit to work, it must make a complete path, beginning at the positive (+) battery terminal and ending at the negative (-) terminal . The negative (-) battery cable is attached to the car's chassis. Therefore, any wire or metal part attached to the chassis provides a good ground path back to the negative (-) battery terminal . Poor ground connections are a major source of driveabílity problems . If any of the main ground connections for the ignition system or the fuel injection system are faulty, the increased resistance in that circuit will cause problems .

Fig. 12 . Main ground for ignition coils on MS 41 .1 engine management system (arrow).

Visually inspect al¡ ground wires and connections for breaks, looseness or corrosion. Be careful because wires sometimes break internally or in areas not easily visible. The main grounds for the DME system are shown in Fig. 11, Fig. 12, and Fig. 13 . Also check the main fuel pump ground in the center console, below the emergency brake handle . If a ground connection has no visible faults, but is still suspect, measure the voltage drop across the connection . A large drop indicates high resistance, meaning the connection is corroded, dirty or damaged. Clean or repair the connection and retest.

DRIVEABILITY TROLIBLESHOOTING

100- 1 4

ENGINE-GENERAL Properly operating fuel injectors play a major role in fuel delivery . The DME ECM switches the injectors on and off at the negative (-) or ground side of the connectors . Posítíve (+) battery voltage is always present at the connectors when the engine is running. An injector that fails or loses power will not open, creating a lean air-fuel mixture and causing the engine to run poorly when cold or stumble on acceleration . An injector that shorts to ground will remain open constantly when the engine is running, creating a rich air-fuel mixture that can dilute engine oil, foul the spark plugs, cause a rough idle, and damage the catalytic converter. Table e lists additional symptoms of common engine driveability problems, their probable causes, and the suggested corrective actions. The entries in bold type in the corrective action column indicate the repair groups where applicable test and repair procedures can be found.

0013131

Fig. 13 . Main chassis ground (arrow) in left front of engine compartment . Fuel Supply

NOTEMost of the symptoms fisted in Table e will also cause the Check Engine light to come on. If the light is on, check for any stored faults as the first step ín troubleshooting driveability complaints.

For the engine to start and run properly, the injection system must deliver fuel in precise proportion to the amount of air entering the engine . To do this, the injection system requires an unrestricted supply of fuel from the fuel pump . If the fuel pump is not working, the engine will not run. If the fuel filter or a fuel line is restricted, the engine may run poorly . If the restriction is severe enough the engine will not start. lf fuel delivery problems are suspected, perform the tests described in 160 Fuel Tank and Fuel Pump . The fuel pressure created by the fuel pump is controlled by a pressure regulator that returns excess fuel to the tank . Any change in fuel pressure will cause a change in the base air-fuel mixture delivered to the engine . If thefuel pressure is too low, the base air-fuel mixture will be lean . lf the fuel pressure is too high, the base mixture will be rich . Fuel pressure tests are described in 160 Fuel Tank and Fuel Pump and 130 Fuel Injection. NOTEFuel pressure tests require a pressure gauge . If this tool ís not avaílable, the tests can be performed by an authorized BMW dealer or other qualified shop.

DRIVEABILITY TROUBLESHOOTING

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ENGINE-GENERAL

100- 1 5

Table e. Engine Driveability Troubleshooting SYMPTOMS a . Engine fafs to start b . Engine starts but stops immediately c . Erratic engine idle d . Poor engine response on acceleration e. Erratic engine operation in al¡ speed ranges f. Excessive fuel consumption g . Poor engine power, fails to rev up h . CO content too low i . CO content too high a a

a a

e h

d a

c c c

Icld

f I

h h

a ~ b ~ c ~ d

Test fuel pump . Repair Group 160

Ignition system faulty

Test ignition system . Repair Group 120

Main relay or fuel pump relay faulty

Test main relay. Repair Group 130

Crankshaft/rpm position sensor faulty

Test crankshaft/rpm sensor. 120

ldle speed control valve faulty

Test idle speed control valve.

Throttle position sensor faulty or idle signal to DME control module missing .

Test throttle position sensor.

Mass air flow sensor faulty

Test mass air flow sensor Repair Group 130

Large air intake system leak

Check for major intake air leaks downstream of mass air flow sensor.

Fuel pressure too low

Test fuel pressure . Repair Group 130

Fuel pressu re to o high

Test fu el pressure . Repair Group 130

h q C oo l ant te mpe r atu re sensor fau lty

f I

I Oxygen sensor faulty

e ~ f

CORRECTIVE ACTION

Fuel pump delivery volume too low

Test fuel pump delivery volume . Repair Group 160 T l n --] est coo a t temperature sensor. Test oxygen sensor.

i ~ Fuel injectors leaking

e ~ f

c a

g ?

CAUSES Fuel pump faulty

g g

e] f

Throttle plate binding or incorrectly adjusted

Check fuel injectors and replace leaking injectors . ~ Repair Group 130 Check throttle plate and adjust if necessary.

Electrical connections loose, broken, or corroded

Visually inspect connectors and correct any faults. Repair Group 600

Ground connections loose, broken, or corroded

Visually inspect ground connections and correct any faults . Repair Group 600

CO content too high CO content too low

Test air flow or mass air flow sensor. Repair ~ Group 130 Test mass air flow sensor.

Input signals to ECM missing, ECM in limp home mode

Make electrical tests at DME ECM relay. Repair Group 130

ECM faulty

Test DME ECM inputs . If all inputs are correct, replace ECM .

DRIVEABILITY TROUBLESHOOTING

ENGINE REMOVAL AND INSTALLATION

110-1

110 Engine Removal and Installation GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110-1 ENGINE REMOVAL AND INSTALLATION 110-1

GENERAL Some special tools are required for removal and installation of the engine . Be sure to have the necessary equipment on hand before starting the job. CAUTION" Engine removal requires disconnecting the battery. This may erase any system fault code(s) that have been stored in control unit memories. Check for fault codes prior to disconnecting the battery cables. " If the Check Engine light is illuminated with the engine running, see 100 Engine-General for On-Board Diagnostics (08D) fault code information. " If any other system faults have been detected, as indicated by an illuminated ANTI LOCK, SRS or AST warning light, see the appropriate repair group in this manual or an authorized BMW dealer for more information on fault codes.

Engine, removing and installing (4-cylinder engines) . . . . . . . . . . . . . . . . . . . . . 110-1 Engine, removing and installing (6-cylinder engines) . . . . . . . . . . . . . . . . . . . . . 110-4

2. Remove transmission from car. See 230 Manual Transmission or 240 Automatic Transmission . 3. Remove engine hood or place hood in service positíon . See 410 Fenders, Engine Hood . NOTEtt is not necessary to remove the engine hood, but it is helpful and will make engine removal and installation easier.

4. Remove splash guard under engine, if applicable . 5. Unbolt ignition coil assembly from bracket on strut tower. Disconnect wiring to ignition cofs, then place coil assembly on engine . 6. Disconnect al¡ cables and harness connectors at throttle housing. 7. Unbolt and remove complete air cleaner housing with mass air flow sensor, disconnecting and labeling connectors, ducting and hoses as necessary. See Fig. 1 .

ENGINE REMOVAL AND INSTALLATION Engine, removing and installing (4-cylinder engines) Cover al¡ painted surfaces before beginning the removal procedure. As an aid to installation, label al¡ components, wires, and hoses before removing them . Do not reuse gaskets, O-rings or seals during reassembly . WARNING Due to risk of personal injury, be sure the engine is cold before beginning the removal procedure.

1 . Disconnect negative (-) cable from battery in luggage compartment . CAUTIONPrior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii.

0011969

Fig. 1. Intake air duct hose clamp (A), mass air flow sensor connector (B), and air cleaner to air flow sensor clips (C) on M44 engine .

ENGINE REMOVAL AND INSTALLATION

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

110-2

ENGINE REMOVAL AND INSTALLATION

8. Drain engine coolant and remove coolant hoses attached to cylinder head . " Drain radiator and engine block. See 170 Radiator and Cooling System . " Disconnect hoses from thermostat housing at front of cylinder head . " Disconnect heater hoses at rear of engine . See Fig. 2. NOTE" The block drain plug is located on the exhaust side towards rear of engine . " Remove small plastic lock clíp to pull radiator drain plug out completely.

10 . Remove radiator cooling fan and radiator as described in 170 Radiator and Cooling System . NOTESome late 4-cylinder models use an electric prímary cooling fan . CAUTIONOn cars with viscous-type cooling fans, the radiator fan has left hand threads.

11 . Remove upper intake manifold, unfasten cable duct from lower intake manifold, crankcase vent valve hose (M44 engine only) 12 . Disconnect fuel supply and fuel return lines, main engine electrical connectors, and lower intake manifold as described in 113 Cylinder Head Removal and Installation . See Fig. 4.

0012687

Fig. 2. Coolant hoses at heater valve and heater core to be disconnected (arrows) . 9. Remove air shroud from top of radiator. See Fig. 3. 0012504

Fig. 4. Crankcase vent valve (A) on top of lower intake manifold of M44 engine . Fuel delivery and retum lines shown at B. Engine harness and sensor connectors shown at C. WARNING " Fuel may be expelled under pressure . Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy. Before disconnecting fuel hoses, wrap a cloth around fuel hoses to absorb any leaking fuel. Plug all open fuel lines. " Always unscrew the fuel tank cap to release pressure in the tank before working on the tank or lines .

Fig. 3. Front air shroud mounting screws (arrows) .

0013137

CAUTION-

I Stuff clean rags into the open intake ports to prevent any parts from falling into the engine intake .

13 . Disconnect vacuum hose from brake booster on bulkhead . Cover both hole in booster and plug hose end. ENGINE REMOVAL AND INSTALLATION

ENGINE REMOVAL AND INSTALLATION

110- 3

14 . Unbolt power steering fluid reservoir from íts mounting bracket. Use stiff wire to hang reservoir to one side . Do not disconnect fluid lines. 15 . Remove power steering pump drive belt and remove pump from its mounting bracket. Use stiff wire to hang pump from body. 16 . On cars with automatic transmission remove front and rear brackets holding automatic transmission cooler lines to engine . 17 . Remove A/C compressor from its mounting bracket without disconnecting any refrigerant lines. See Fig. 5. 0011967

Fig. 6. Front exhaust pipe to exhaust mounting nuts (arrows), as viewed from below on 4-cylinder engine . 23 . Carefully raíse engine out of car, checking for any wiring harnesses, fuel lines, or mechanical parts that might become snagged as engine is removed. 24 . Installation is reverse of removal, noting the following: " Replace all gaskets, O-rings and seals. " Change engine oil and filter and check al¡ other fluid levels . See 020 Maintenance Program. " Refill and bleed cooling system . See 170 Radiator and Cooling System . " Insta¡¡ the front exhaust pipes using new gaskets and self-locking nuts . Use copper paste on threads. See 180 Exhaust System .

Fig. 5. A/C compressor mounting bolts (arrows) . 18 . Move A/C compressor out of way without distorting or damaging any lines. Support compressor by hanging it from chassis using stiff wire . 19 . Disconnect wiring from starter and alternator . Move wiring harness out of way. See 121 Battery, Starter, Alternator. 20 . Remove oil dipstick guide tube . Note O-ring at base of tube when removing .

Tightening Torques " Coolant drain plug to cylinder block . 25 Nm (18 ft-Ib) " Engine mount to subframe -1b) , M8 . . . . . . : . . . . . . . . . . . . . . . , : . . 22 Nm (17 ft M10 . . . . . . . . . . . . . . . . . . . . . . . 45 Nm (33 ft'-Ib) " Intake manifold to cylinder head M7 . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 ft-Ib) M8 . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft-Ib) ` " Radiator cooling fan to coolant pump40 Nm (30 ft-Ib) " Radiator drain screw to radiator . . . 2 .5 Nm (22 in-lb) " Wiring to alternator (M8 nut) . . . . . . . . 12 Nm (9 ft-1b) " Wiring to starter M6 nut . . . . . . . . . . . . . . . . . . . . . . .. :5 Nm (44 in-lb) M8 nut . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm (9 ft-Ib)

21 . Remove front exhaust pipe from exhaust manifold . See Fig. 6. 22 . Install an engine lifting device and raise engine until its weight is supported. Remove nuts and ground strap from left and right engine mounts .

ENGINE REMOVAL AND INSTALLATION

110-4

ENGINE REMOVAL AND INSTALLATION

Engine, removing and installing (6-cylinder engines) Engine removal procedures for the various 6-cylinder engines are covered in this section. Most steps in the procedures are similar or the same for al¡ engines. Specific differences that apply are noted at the beginning of each step . Be sure to cover all painted surfaces before beginning the removal procedure. As an aid to installation, label all components, wires, and hoses before removing them . Do not reuse gaskets, O-rings or seals during reassembly . WARNING Due to risk of personal injury, be sure the engine is cold before beginning the removal procedure .

1 . Disconnect negative (-) battery cable in luggage compartment . CAUTIONPrior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡.

2. Remove engine hood or place hood in service position . See 410 Fenders, Engine Hood .

Fig. 7. Remove main harness from top engine and place at base of windshield .

NOTE1t is not necessary to remove the engine hood, but it helpful and will make engine removal and installation easier.

3. Remove splash guard under engine, if applicable . 4. Remove transmission from car. See 230 Manual Transmission or 240 Automatic Transmission . 5. Remove vacuum hose from brake booster on bulkhead . Cover hole in booster and plug hose end . 6. Remove intake air plenum panel in rear of engine compartment . See 640 Heating and Air Conditioning . 7. Remove ground strap from timing case cover, if applicable. 8. Remove top engine covers and disconnect ignition coil harness connectors . Working at fuel injectors, pry open small wire clips at each injector . Remove main harness hold-down nuts and lift complete harness away. See Fig. 7. 9. Unbolt and remove complete air cleaner housing with mass air flow sensor, disconnecting and labeling connectors, ducting and hoses as necessary. See Fig. 8.

ENGINE REMOVAL AND INSTALLATION

0012703

Fig. 8. Mass air flow sensor connector air duct hose clamp, and air cleaner housing mounting bolts (arrows) . 10 . On cars with automatic transmission, remove front and rear brackets holding transmission cooler lines to side of engine .

ENGINE REMOVAL AND INSTALLATION

110-5

11 . Draín engine coolant and Rmove coolant hoses attached to cylinder head . " Drain engine block by removing block drain. " Disconnect hoses from thermostat housing in front of cylinder head . " Disconnect heater hoses at rear of engine . See Fig . 9. " Drain radiator by removing threaded plastic plug from lower left comer. NOTE" The block drain plug is located oh the exhaust side towards rear of engine. " Remove small plastic lock clip to pulí radiator draín plug out completely.

uu12ivu Fig. 10. Throttle housing assembly on M52 engine . Disconnect hoses, cables and harness connectors at and around housing.

Fig. 9. Coolant hoses at heater valve and heater core to be disconnected (arrows) . 12 . Remove radiator cooling fan and radiator as described in 170 Radiator and Cooling System . CAUTIONRadiatorfan has left hand threads.

13 . Label and disconnect coolant hoses, cables, and harness connectors from throttle housing. See Fig. 10 . 14 . Working at rear of intake manifold, label and then remove fuel supply and fuel retum lines. Disconnect fuel lines from support bracket on manifold . See Fig. 11 . NOTEOn M52 and S52US engines, special fittings are used to retain the fuel lines to the fuel rail. Use BMW special tool no. 161050 to compress the locking clip inside the end of the fuel line fittings to release the fine .

15 . Unbolt power steering fluid reservoir from its mounting bracket. Use stiff wire to hang reservoir to one side . Do not disconnect fluid fines.

0012699

Fig. 11 . Special fuel line fitting at fuel rail on M52/S52US engine . Use BMW special tool 16 1 050 to release locking fittings at ends of fuel lines . WARNING " Fuel may be expelled under pressure . Do not smoke or work near heaters or other fire hazards. Keep a fire extinguísher handy. Before disconnecting fuel hoses, wrap a cloth around fuel hoses to absorb any leaking fuel. Plug all oyen fuel fines. " Always unscrew the fuel tank cap to release pressure ín the tank before working on the tank or lines.

16 . Remove intake manifold from engine by removing seven mounting nuts from above and two mounting bracket boits from below. See Fig. 12 . CAllTIONStuff clean rags into the open intake ports to prevent any parts from falling into the engine intake.

ENGINE REMOVAL AND INSTALLATION

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ENGINE REMOVAL AND INSTALLATION

Fig . 12 . Intake manifold mounting nuts on 6-cylinder engine . Also remove two bolts from support brackets (arrows) . 17 . Working below intake manifold, disconnect harness connectors . Cut wire ties holding engine harness to bulkhead and disconnect main engine harness connector at rear of engine compartment . See Fig . 13 .

Fig . 14 . Power steering pump mounting bolts (arrows) . M52 engine shown . 21 . Remove A/C compressor from its mounting bracket without disconnecting any refrigerant lines . See Fig . 15 .

0013132

Fig. 13 . Main engine harness connectors in rear of engine compartment (arrow) . 18 . Remove poly-ribbed drive belt(s) . 19 . Remove engine drive belt . See 020 Maintenance Program .

Fig . 15 . A/C compressor mounting bolts (arrows) .

20 . Remove power steering pump from its mounting bracket . See Fig . 14 . Use stiff wire to hang pump from body.

ENGINE REMOVAL AND INSTALLATION

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22 . Move A/C compressor out of the way without distorting or damaging any lines. Support compressor by hanging it from chassis using stiff wire.

26 . Carefully raise engine out of car, checking for any wiring, fuel lines, or mechanical parts that might become snagged as engine is removed.

23 . Disconnect wiring from starter and alternator. Move wiring harness out of the way. See 121 Battery, Starter, Alternator.

27 . Installation is reverse of removal, noting the following:

24. Remove Font exhaust pipe from exhaust manifold . See Fig. 16 .

0012525

Fig. 16 . Front exhaust pipe to exhaust manifolds mounting nuts on 6cylinder engine (arrows).

Replace al¡ gaskets, O-rings and seals. " Change engine oil and filter and check all other fluid levels. See 020 Maintenance Program. " Refill and bleed cooling system . See 170 Radiator and Cooling System . " Check that engine drive belts properly engage the pulley grooves. " Install the Font exhaust pipes using new gaskets and seif-locking nuts. Use copper paste on threads. See 180 Exhaust System . Tightening Torques " Coolant drain plug to cylinder block . 25 Nm (18 ft-Ib) " Engine mount to subframe M10 . . . . . . . . . . . . . . . . . . . . . . . . . 45 Nm (33 ft-Ib) M8 . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft-Ib) " Intake manifold to cylinder head M7 . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 ft-Ib) M8 . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft-Ib) " Radiator cooling fan to coolant pump40 Nm (30 ft-Ib) " Radiator drain screw to radíator . . . 2.5 Nm (22 in-lb) " Wiring to alternator (M8 nut) . . . . . . . . 12 Nm (9 ft-Ib) " Wiring to starter M6 nut . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (44 in-lb) M8 nut . . . . . . . . . . . . . . . . . . . . . . . . 12 Nm (9 ft-Ib)

25 . Install an engine lifting device and raise engine until its weight is supported. Remove nuts and ground strap from left and right engine mounts .

ENGINE REMOVAL AND INSTALLATION

CYLINDER HEAD REMOVAL AND INSTALLATION

113-1

113 Cylinder Head Removal and Installation GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113-1 CYLINDER HEAD, 4-CYLINDER . . . . . . . . 113-1

Cylinder head, removing (4-cylinder engine) . . . 113-1 Cylinder head, installing (4-cylinder engine) . . . 113-6

CYLINDER HEAD, 6-CYLINDER . . . . . . . 113-10

Cylinder head, removing (6-cylinder engine) . . 113-10 Cylinder head, installing (6-cylinder engine) . . . 113-15

GENERAL

CYLINDER HEAD, 4-CYLINDER

The information given in this repair group assumes that the engine is installed in the engine bay. For cylinder head, camshaft, and valvetrain disassembly and reconditioning information, see 116 Cylinder Head and Valvetrain .

Cylinder head, removing (4-cylinder engine)

In the procedures given below, engines are referred to by engine code . If necessary, see 100 Engine-General for engine code and application information . NOTEIf a head gasket problem is suspected, a compression test will usually detect the fault. See 100 Engine-General for compression testing information .

Special BMW service tools are required to properly remove and install the cylinder head on both the 4-cylinder and 6-cylinder engines. The special tools are used to time the valvetrain to the crankshaft and to remove the Torx (El 2) head bolts. Read the procedure through before beginning the job. Cover al¡ painted surfaces before beginning the removal procedure . As an aid to installation, label all components, wires, and hoses before removing them . Do not reuse gaskets, O-rings or seals during reassembly . WARNING Due to risk of personal injury, be sure the engine is cold before beginning the removal procedure.

For ease of use this removal procedure is broken into subsections, as follows: General Cooling system, draining Cylinder head cover, removing Intake manifold, removing Timing chains, uncoupling Cylinder head assembly, removing WARNING Allow engine to cool before beginning this procedure.

General 1 . Disconnect negative (-) cable from battery. CAUTION " Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii. " Disconnecting the battery may erase fault codees) stored in control module memory. Check for fault codes using special BMW diagnostic equipment. NOTEThe battery is mounted in the luggage compartment behind the right side trim panel.

2. Working underneath vehicle, remove front exhaust pipe from exhaust manifold . See Fig. 1 . 3. Disconnect vacuum hose fitting from brake booster on rear bulkhead . Plug opening in booster and hose end.

CYLINDER HEAD, 4-CYLINDER

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113-2

CYLINDER HEAD REMOVAL AND INSTALLATION 7. On M42 engines, disconnect hose from coolant pipe on left side of engine . See Fig. 3.

0011s6i

Fig. 1 .

Front exhaust pipe to exhaust manifold mountíng nuts (arrows) .

4 . Remove air filter housing complete with mass air flow sensor and attached hoses and ducting . See Fig . 2 .

-1

Fig . 3 .

0013023

Coolant hose connection beneath intake manifold on M42 engine (arrow) .

8. Disconnect heater hoses from coolant flange on rear of cylinder head . Cylinder head cover, removing 9. Remove ignition coil pack from right strut tower. See Fig . 4.

0011969

Fig . 2. Air filter housing/air intake connections on M44 engine with traction control . Clamp at throttle housing (A) ; mass air flow sensor connector (B) ; and clips at upper air filter housing (C) .

Cooling system, draining 5 . Drain coolant from engine block and radiator. See 170 Radiator and Cooling System . NOTE" The block drain is on the exhaust side of the engine, near cylinder no. 4 . " The radiator drain plug is on the bottom of the radiator on the driver's side. Remove small plastic lock clip to pull radiator drain plug out completely.

6. Disconnect hoses from coolant flange/thermostat housing on front of cylinder head . Unbolt thermostat housing from cylinder head . CYLINDER HEAD, 4-CYLINDER

Fig . 4 .

0011995

Cylinder head cover showing location of engine breather hose (A), wiring harness duct (B), and ignition coil pack (C) . M44 engine shown . Cover on M42 engine is similar.

10 . Disconnect engine breather hose from cylinder head cover.

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113-3

11 . Detach wiring harness duct at rear bulkhead panel and pull complete duct forward and up to allow access to rear of cylinder head cover. 12 . Remove spark plugs and spark plug wire loom . " Remove plastic cover from top of cylinder head . " Disconnect spark plug wires from spark plugs and remove spark plugs. " Unbolt spark plug cable harness and heat shield from right side of cylinder head cover and set aside . 13 . Unscrew and remove cylinder head cover cap screws and remove cover. See Fig. 5. CAUTION-

Two of the cover hold-down screws are under the spark plug cable duct. NOTEMake note of the arrangement of cap screws, washers and rubber grommets holding the cylinder head cover in place.

0012686

Fig. 6. Intake manifold support brackets and mounting hardware. Manifold for M44 engine shows. 16 . Disconnect oil dipstick tube bracket from lower manifold section. 17 . On M44 engine, relieve fuel pressure using compressed air (maximum 3 bar pressure) at schroeder valve on fuel rail . Briefly apply air pressure to force fuel back into fuel tank . See Fig. 7.

Fig. 5. Cylinder head cover mounting points (arrows) . Intake manifold, removing 14 . On late engines, disconnect injector air shrouding hose from fitting at center of upper intake manifold . 15 . Remove upper section of intake manifold . " Disconnect ali cables harness connectors from throttle housing and intake manifold . " Disconnect fuel tank vent hose from vent valve on lower sitie of manifold . " Remove manifold support brackets . See Fig. 6. " Remove upper-to-lower manifold fasteners (1 bolt, 2 nuts) and separate upper manifold from lower manifold . Note locating dowei sleeves on lower to upper manifold mounting studs. Remove dowels and set aside. See Fig. 8.

Fig. 7. M44 fuel rail air connection (A) and fuel supply and return lines (B). 18. Disconnect fuel supply and return lines from fuel rail . WARNING " The fuel system retains fuel pressure when the engine is off (up to 75 psi) . Use care when disconnecting fuel lines. Unscrew the fuel tank cap to retease pressure in the tank. Wrap a clean shop towel around the fitting when loosening. " Fuel is highly flammable . When working around fuel, do not disconnect any wires that could cause electrical sparks. Do not smoke or work near heaters or other tire hazards. Place a tire extinguisher in the vicinity of the work area .

19 . Disconnect coolant hoses from vent valve on lower intake manifold . Remove crankcase vent valve from manifold . CYLINDER HEAD, 4-CYLINDER

113-4

CYLINDER HEAD REMOVAL AND INSTALLATION

20 . Disconnect main engine wiring harness connector. Label and disconnect harness connectors for crankshaft and camshaft sensors. See Fig. 8.

Fig. 9. Upper timing chain cover bolts (arrows) . Remove secondary air injection check valve from hose (A) on M44 engine . Remove cylinder identification sensor from chain cover (B). 0012504

Fig. . Crankcase vent valve (A), camshaft and crankshaft sensor harness connectors (B), locating bushings (C), main engine wiring harness connector (D). M44 engine shown . NOTEEarly engines do not have a maín disconnect at the lower intake manifold harness. lf necessary, remove the cable ducting bolts and set harness ducting aside .

21 . Remové lower section of intake manifold . " Remove Yshaped support bracket from underside of manifold . (See Fig . 6.) " Unbolt support brackets from alternator and starter. " Remove nuts holding manifold to cylinder head and pull manifold back until harness connectors for oil pressure switch and coolant temperature sensor are accessible . Label and disconnect connectors, then remove manifold and set aside. Timing chains, uncoupling

0011998

Fig. 10. Engine set to approximate TDC . Cylinder no . 1 camshaft lobes face in and arrows on sprockets poínt up (arrows) .

22 . On M42 engines, remove thermostat housing from upper timing chain cover.

26 . Lock crankshaft in TDC position by insertíng BMW special tool no . 11 2 300 through bore and into hole in flywheel or drive plate. See Fig. 11 .

23 . On late M44 engines (January 1997 and later), remove secondary air injection check-valve from front of engine and lay aside.

NOTE" If necessary, remove plug from locating bore in lower edge of bell housing to insert locking tool.

24 . Remove cylinder identification sensor from upper timing chain cover. Remove upper timing chain cover. See Fig . 9 .

" Confirm that the locking tool has been correctly installed by trying to rotate the crankshaft.

25 . Set engine to approximate TDC by rotating in normal operating direction until camshaft lobes at cylinder no. 1 are facing each other. See Fig . 10 .

CYLINDER HEAD, 4-CYLINDER

27 . Lock camshafts at TDC by mounting BMW specíal tool no . 113 240 over square ends of camshafts. See Fig. 12 . NOTECheck that tool is squarely seated on cylinder head gasket surface. If necessary, rotate camshafts slightly using an open-end wrench at hex on camshafts.

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113-5

Fig . 13. Hydraulic chain tensioner (arrow) .

Fig . 11 . BMW special tool no . 11 2 300 installed through bellhousin and finto flywheel (arrow) to lock crankshaft at TDC .

6011966

Fig . 12 . BMW special tool no . 11 3 240 installed on rear of camshafts to hold them at TDC . (M44 engine shown . Other engínes are similar.)

uu 11999

Fig . 14. Chain guide and guide adjusting sleeve (arrow) . Allen-head retaining screw has been removed . Use slotted screwdriver to loosen adjusting sleeve .

CAUTIONThe camshafts must be locked in the TDC position using the special service tool, or equivalent, before removing the timing chaín . The tool holds the camshafts parallel to each other and perpendicular to the valve cover gasket surface .

NOTEIt is not necessary to remove the cam sprockets from the chain untess these parts are being reptaced. tire tie each sprocket to the chain to keep the sprockets timed to each other. Keeping the sprockets timed will símplífy instaftation .

28 . Remove hydraulic chain tensiones from right side of cylinder head . See Fig . 13 . 29 . Remove mounting bolts from left and right camshaft sprockets . Then remove camshaft sprockets from cam-

shafts . On M44 engines, note orientation of sensor wheel. 30 . Remove upper bolt from left chain guide. Loosen chain guide adjusting sleeve approximately two turns. See Fig. 14 .

Cylinder head assembly, removing

31 . Remove crankshaft locking tool (BMW special tool no. 11 2 300) . Using the crankshaft vibration damper bolt, turn engine opposite its normal direction of rotation (counterclockwise as viewed from the front) approxi mately 45°. This prevents accidental contact between valves and pistons during installation . CYLINDER HEAD, 4-CYLINDER

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CYLINDER HEAD REMOVAL AND INSTALLATION

32 . Using Torx E12 socket, remove cylinder head bolts in the sequence indicated. See Fig. 15 . Remove cylinder head and head gasket . Discard head boits.

2. Check gasket surface of cylinder head and cylinder block for warpage using a straight edge .

3. On M42 engine: Be sure oil feed check valve and spacer are correctly positioned in block. See Fig. 16 .

0012502

Fig. 15. Cylinder head bolt loosening sequence . UseTorx El 2 socket.

Cylinder head, installing (4-cylinder engine) CAUTIONIf the camshafts were removedrínstalled while the cylinder head was off, a minimum wafting time ís requíred after installing the camshafts. When the camshafts are removed, the hydraulic lifters can expand. This expansion can cause fncreased valve lift, resultíng in open valves and pfston contact

Cylinder head installation waiting times " At or above 68°F (20°C) . . . . . . . . . . . . . . . 10 minutes " 50-68°F (10-20°C) . . . . . . . . . . . . . . . . . . . 30 minutes " 32-50°F (0-10°C) . . . . . . . . . . . . . . . . . . . . 75 minutes 1 . Clean cylinder head and gasket surfaces of cylinder block and al¡ timing chain covers . " Remove al¡ foreign matter and any ¡¡quid from bolt holes, then clean with a thread chaser. CAUTIONDo not use a metal scraper or wire brush to clean the alumfnum cylinder head or pistons. If necessary, use a hard wooden or plastic scraper. Also available are abrasive discs to be used ín conjunction wíth an electric dril¡. Be sure to use the correct disc for the type of metal being cleaned.

Fig. 16 . Oil feed check valve and spacer used on M42 engine. Install check valve wíth collar (arrow) facing down . CAUTIONIf the check valve is not installed correctly, oil flow to the cylinder head would be restrícted.

4. Place new cylinder head gasket on surface of cylinder block. Check that two locating dowels are correctly positioned in block and not damaged. CAUTIONThe word "OBEN", prfnted on the gasket, should face up.

5. Place new rubber profile gasket in groove of front cover. 6. With camshafts locked in TDC position with BMW special tool as described earlier, set cylinder head in position . CAUTION" The camshafts must be focked in the TDC position at the rear of the cylinder head with BMW specfal tool no . 113 240 before installing the cylinder head. " Make sure the crankshaft, which had been rotated approximately 45° opposite the dfrection of engine rotation, is still in that position before lowering the cyffnder head ínto position . " Torx-type cylinder head bolts should not be reused. They are stretch-type bolts and must always be replaced whenever loosened.

CYLINDER HEAD, 4-CYLINDER

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113-7

7. Lightly lubricate new cylinder head bolts. Loosely instan bolts and their washers, then thread them in until they are finger tight. NOTECheck that all washers for the cylinder head bolts are in place before installing the bolts.

8. Tighten cylinder head bolts in correct sequence. See Fig. 17 .

Fig. 18. Protractor and pointer being used to tighten bolts to specified torque angle (6-cylinder engine shown) .

UU125U2

Fig. 17. Cylinder head bolt tightening sequence for 4-cylinder engines. Note oil supply tube seal (arrow) on M44 engine . WARNING The bolts should be tightennd in three stages as lísted below. The final stages require the use of a special tool (BMW tool No. 11 2 110) or a suitable protractor to tighten the bolts to a specified torque angle. See Fig. 18 .

Tightening Torques " Cylinder head to engine block (Torx El 2 M10 bolts) Stage 1 . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft-Ib) Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +90° Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +90° 9. Carefully rotate crankshaft in direction of engine rotation and lock it at TDC by inserting BMW special tool no. 11 2 300 through transmission bellhousing . See Fig. 19 . CAUTION-

Be sure timing chain does not bind on crank gear when turning crankshaft.

Fig. 19 . BMW special tool 11 2 300 inserted through bellhousing hole and finto flywheel (arrow) to lock crankshaft at TDC. 10 . Turn left chain guide adjusting sleeve in until it just contacts the cylinder head (See Fig. 14 .) . Insert chain guide retaining screw and tighten. 11 . Place chain sprockets with chains on camshafts so that arrows on sprockets point up and elongated holes in sprockets are centered to tapped holes in camshafts. See Fig. 20 .

CYLINDER HEAD, 4-CYLINDER

CYLINDER HEAD REMOVAL AND INSTALLATION

113-8

IW?

'/~f "

Detent ring

Outer sl eve

;,s

Spri g i

Snap /0 .13024 ring up and camshaft threaded holes centered in siotted holes. 12 . On M44 engine : Place sensor wheel on intake camshaft sprocket so that arrow on sensor wheel points up . 13 . Instan and hand-tighten sprocket mounting bolts. CAUTION-

Different hydraulic chain tensioners were used during manufacture, depending on engine type . See Fig. 21 . Note that the late style tensioner can be retrofitted to the earlier engine, so be sure to identify the version of tensioner installed as instalation instructions vary between the two.

14 . On M42 engine: Disassemble chain tensioner by striking outer sleeve against a solid object . This will release snap ring and tensioner will separate . See Fig. 22 . M42 Engine

Fig. 22. Disassembled chain tensioner for M42 engine . 15 . On M42 engine : Clamp tensioner piston in vice (soft jaws). Slowly compress piston, making sure detent ring fits into taper of outer sleeve . If necessary, press ends of detent ring together. Slowly continue pressing tensioner together until snap ring audibly clicks into outer sleeve . Measure overall length of tensioner to confirm correct assembly : 68 .5 mm (2 .7 in .) . NOTEThe late-style tensioner on the M44 engíne can be retrofitted to the M42 engine.

Tightening Torque " Chain tensioner plug to cylinder head . . . . . .-~ . . . . . . . . . . 40 Nm (30 ft-Ib) 16 . On M44 engíne : Clamp tensioner píston in vice (soft jaws) and squeeze oil from it. Slowly compress piston only up to end circlip . Repeat procedure twice to ensure all oil is expelled . See Fig. 23 . 17 . Instan hydraulic chain tensioner to cylinder head . Use a new sealing washer on tensioner when installing . 18 . On M42 engine : Unlock chain tensioner by pressing chain rail against tensioner until it expands out.

0013024a

Fig. 21 . Two versions of hydraulic chain tensioners . Original chain tensioner on M42 engine (top) can be disassembled . Chain ten sioner on M44 engine (bottom) cannot be disassembled . Note differences in outer sleeve . Also, the M42 tensioner detent ring groove (arrow) is visible when tensioner is extended .

19. Check that chain is free of slack. Tighten sprocket mounting bolts. Tightening Torque " Chain sprocket to camshaft flange . . . 10 Nm (89 in-lb) 20 . Remove crankshaft locking tool from bellhousing and camshaft locking tool from rear of cylinder head .

CYLINDER HEAD, 4-CYLINDER

CYLINDER HEAD REMOVAL AND INSTALLATION

113-9

NOTEOn M44 engines, reptace sea¡ for oil supply tube . See Fig . 17.)

0012507

Fig . 23 . When reinstalling chain tensioner on M44 engine, old oil in tensioner piston must be expelled by compressing piston in vise . When compressing piston, only compress up to end circlip (arrow) . 21 . Turn engine over by hand in direction of rotation at least two fui¡ rotations . Reinstall camshaft and crankshaft locking tools to check engíne timing . Remove locking tools if no faults are found .

Fig . 25 . Rear of cylinder head cover showing area where sealant (arrows) should be applied . Inset shows cylinder head cover mounting bolt and insulator assembly : M6 screw (1), rubber damper (2), washer (3) .

22 . Insta¡¡ upper timing chain cover. " Install gaskets and instan cover using two mounting bolts . Using a screwdriver, lever down on front cover until cover gasket surface is flush with cylinder head gasket surface. See Fig . 24 . Tighten two bolis. " Insta¡¡ and tighten remainder of bolis .

Fig . 24 . Install upper timing case cover with two bolis, then press down on cover so that top surface is flush with cylinder head (arrow) . Hold cover in position and tighten bolis .

Tightening Torque " Cylinder head cover to cylinder head (M6 screws) . . . . . . . 10 Nm (89 in-lb) 24 . Installation of remaining parts is reverse of removal, noting the following : " Make sure al¡ sealing surfaces are clean and free of old gasket material . Install new intake manifold gasket . " On M44 engine : Replace seals above and below crankcase vent valve . " When installing lower intake manifold, make sure hollow locating bushings are on two lower studs . " Reinstall harness connectors for oil pressure switch and coolant temperature sensor before installing intake manifold . Tighten manifold nuts in stages . " Refill cooling system as described in 170 Radiator and Cooling System . " Change engine oil and filter as described in 020 Maintenance Program . " If necessary, adjust accelerator cable . " Run engine at approx . 3,500 rpm for about 20 seconds to allow hydraulic chain tensioner to fill with oil . " Reconnect battery last .

23 . Install cylinder head cover. " Clean old gasket glue from sealing surfaces . Use a small amount of 3-Bond®1209 adhesive or equivalent at corners of half-moon cut-outs at back of cylinder head . See Fig . 25 . CYLINDER HEAD,

-CYLINDER

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CYLINDER HEAD REMOVAL AND INSTALLATION

Tightening Torques " Coolant drain plug to cylinder block . . 25 Nm (18 ft-1b) " Intake manifold support to manifold . . 15 Nm (11 ft-Ib) " Lower intake manifold to cylinder head . . . . . . . . . . . . . . . . . 15 Nm (11 ft-Ib) " Lower intake manifold to upper manifold . . . . . . . . . . . . . . . . 15 Nm (11 ft-Ib) " Radiator cooling fan to coolant pump . 40 Nm (30 ft-Ib) " Radiator drain screw to radiator . . . . 2 .5 Nm (22 in-lb)

CYLINDER HEAD, 6-CYLINDER Cylinder head, removing (6-cylinder engine) For ease of use this procedure is broken into subsections, as follows:

Cooling system, draining 5. Drain engine coolant and Rmove coolant hoses from thermostat housing. Drain engine block by removing block drain. See 170 Radiator and Cooling System . NOTEThe block drain is on the exhaust side of the engine, near cylinder no. 5.

6. Remove radiator cooling fan and fan shroud . See 170 Radiator and Cooling System . NOTEThe radiator cooling fan nut (32 mm wrench) has lefthand threads .

7. Disconnect heater hoses at rear of cylinder head . See Fig. 26 .

General Cooling system, draining Cyiinder head cover, removing Intake manifold, removing Timing chains, uncoupling Cylinder head assembly, removing WARNING Allow the engine to cool before beginning this procedure .

General 1 . Working inside luggage compartment, disconnect negative (-) battery cable. CAUTION" Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡. " Disconnecting the battery may erase fault code(s) stored in control module memory. Check for fault codes using special BMW diagnostic equipment

2. Remove front exhaust pipes from manifolds. Discard nuts. 3. Remove air filter housing complete with mass air flow sensor and intake air ducting. Disconnect vacuum hoses from throttle housing . 4. On M52 and S52US engines: Remove secondary air injection check-valve from front of engine and set aside.

CYLINDER HEAD, 6-CYLINDER

0012687

Fig. 26 . Disconnect heater hoses at heater valve (A) and heater core (B). 8. Remove alternator cooling duct . Cylinder head cover, removing 9. Remove air plenum from rear of engine compartment. See 640 Heating and Air Conditioning . 10 . Remove plastic cylinder head covers from above fuel injectors and ignition coils. Pull larger cover forward when removing . See Fig. 27 . 11 . Disconnect crankcase ventílation hose fitting from cylinder head cover. 12 . Disconnect ignition coil harness connectors from coiis. Remove ignition coiis and spark plugs. See 120 Ignition System .

CYLINDER HEAD REMOVAL AND INSTALLATION

113- 1 1

15 . Remove oil baffle cover from above intake camshaft . See Fig . 29 .

Fig . 27 . Remove top engine covers by prying out plugs and removing nuts (A) . Make sure rubber insulators on either side of large cover do not fall off during cover removal (B) . 13 . Remove hold down nuts/bolts from fuel injection harness . Pry back injector connector retaining clips and lift

entire harness off engine . See Fig. 28 .

Fig . 29 . Camshaft oil baffle cover being removed .

811119

NOTEThe cylinder head cover mounting bolt insulators and gaskets should be reinstalled in the same order. Make note of their arrangement during removal.

Intake manifold, removing

16 . Disconnect vacuum hose from brake system vacuum booster . Plug opening in booster. 17. Remove throttle housing mounting bolts and remove throttle housing. Set throttle housing aside without disconnecting cables or coolant hoses. See Fig. 30 .

Fig . 28 . Fuel injection harness beíng lifted off engine to be placed at base of windshield (A) . Ignition coils are also visible (B) . M50 engine shown, other 6-cylinder engines are similar. 14 . Remove cylinder head cover mounting bolts and remove cylinder head cover.

Fig. 30 . Remove 4 comer bolts (arrows) from throttle housing and unbolt complete assembly from intake manifold . Remove complete throttle assembly without disconnecting connectors, hoses or cables . (M50 engine shown .)

CYLINDER HEAD, 6-CYLINDER

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CYLINDER HEAD REMOVAL AND INSTALLATION

18 . Working from underside of intake manifold, disconnect harness connectors, vent hoses, and air bypass hoses) . 19 . Working at rear of intake manifold, label and disconnect fuel supply and fuel return lines. Remove fuel line hold down bracket to free lines. See Fig. 31 .

21 . Detach oil dipstick guide tube from manifold . Discon nect vent hose at base of dipstick . 22 . Remove intake manifold from engine by removing seven mounting nuts from above and two support bracket bolts from below. See Fig. 32 .

NOTEOn M52IS52US engines, a special fitting is used to retain the fuel fines to the fuel rail. Use BMW special tool no. 16 1 050 to expand the locking clip inside the end of the fuel líne fittings.

Fig. 32 . Intake manifold nuts and support bracket bolts (arrows) . CAUTIONStuff clean rags into the open intake ports to prevent any ports from falfing into the engine .

001269s

Fig. 31 . Fuel lines at intake manifold on M52/S52 engine . Use BMW special tool 16 1 050 to release locking fittings at ends of fuel enes . WARNING " The fuel system is desígned to retan pressure even wheh the ignition is off. When working with the fuel system, loosen the fuel lines slowly to allow residual fuel pressure to dissipate gradually. Avoid spraying fuel. " Fuel is highly flammable . When working around fuel, do not disconnect any wires that could cause electrfcal sparks. Do not smoke or work near heaters or other fire hazards. " Always unscrew the fuel tank cap to release pressure in the tank before working on the tank or lines.

20 . Remove mounting screws and release wiring harness duct at rear bulkhead and move aside. Remove wiring harness brackets from bulkhead .

CYLINDER HEAD, 6-CYLINDER

Timing chains, uncoupling

23 . Remove VANOS unit from front of cylinder head . See VANOS section in 117 Camshaft Timing Chain. 24 . Set engine to approximate TDC by rotating in normal operating direction until camshaft lobes at cylinder no. 1 are facing each other. Arrows on camshaft sprockets should be pointing up . NOTETo confirm that the crankshaft is set to the TDC position, check that the OIT mark (0° TDC) on the front lower timing chain cover ís aligned with the víbration damper See Fig. 33.

25 . Lock crankshaft at TDC.

" Insert BMW special tool no . 11 2 300 through transmission bellhousing and finto hole in flywheel or drive plate. See Fig. 34 .

CYLINDER HEAD REMOVAL AND INSTALLATION

113- 1 3

Fig. 35. Camshaft locking tool (BMW special tool no . 11 3 240) installed on rear of camshafts. (M44 engine shown. Other engines are similar.)

Fig. 33 . Crankshaft is positioned at TDC when notch oh front timing chain cover is aligned with 0/T mark on víbration damper.

CAUTIONThe camshafts must be locked in the TDC position using the special service tool before removing the timing chain. The arrows on the sprockets should not be used to accurately set the engine to TDC. The tool holds the camshafts parallel to each other and perpendicular to the cylinder head cover gasket surface.

27 . Depress secondary timing chain tensioner and lock t down by inserting BMW special tool no. 113 292. Alternatively, a stiff piece of wire can be used . See Fig .,36 .

Fig. 34. Crankshaft locking tool (BMW special tool 11 2 300) inserted through bellhousing hole and finto flywheel (arrow) . 26 . Lock camshafts at TDC.

" Remove three cylinder head cover mounting studs from across rear of head, if applicable. " Mount BMW special tool no . 11 3 240 over square ends of camshafts. Check that tool is squarely seated on cylinder head gasket surface. If necessary, rotate camshafts slightly using a 24 mm wrench at hex on camshaft(s) . See Fig. 35 .

Fig. 36 . Press secondary tensioner down fully and insert wire through holes (arrow) to lock . Timing chain tensioner varies depending on engine (M52 engine tensioner shown) . 28 . Remove mounting nuts from front of intake camshaft sprocket . Remove camshaft sprocket, thrust washer(s), and where applicable, spring plate. NOTEWhere applicable, make note of thrust washer positions. The thicker (0 .4 mm) washer is mounted outermost.

CYLINDER HEAD, 6-CYLINDER

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CYLINDER HEAD REMOVAL AND INSTALLATION

29 . Remove mounting nuts from front of exhaust camshaft sprocket . Remove secondary sprockets together with timing chain from front of camshafts. CAUTIONThe crankshaft must not be allowed to rotate once the camshaft timing chain is removed. The pistons can contact the valves. NOTEDo not remove the sprockets from the chain unless these parts are being replaced. Wire tie each sprocket to the chain to keep the sprockets timed to each other.

30 . Unbolt secondary timing chain tensioner from top of cylinder head . 31 . Remove primary timing chain tensioner from side of cylinder head . See Fig. 37 .

Fig. 38 . Timing chain guide mounting bolts (arrows) . M50 engine shown.

Fig. 37. Primary timing chain tensioner (arrow). WARNING Remove tensioner slowly-¡t ís under spring pressure.

32 . Remove timing chain guíde (Tono E8 socket) . See Fig. 38 . 33. Lift primary chain sprocket off exhaust camshaft . Remove sprocket from chain . Suspend chain using stiff wire . Cylinder head assembly, removing

34 . Remove two mounting bolts holding cylinder head to lower timing chain cover (Torx E8 socket). See Fig . 39 .

CYLINDER HEAD, 6-CYLINDER

Fig. 39 . Cylinder head-to-timing chain cover mounting boits (arrows) . (Bolt A also retains secondary chain tensioner.) 35 . Using BMMI special tool no . 11 2 250 or an equivalent tool, loosen cylinder head bolts in several stages . See Fig. 40 . Discard head boits. CAUTIONTorx-type cylinder head bolts should not be reused. Theyare stretch-type bolts and must atways be replaced whenever loosened.

CYLINDER HEAD REMOVAL AND INSTALLATION

113- 1 5

1 . Clean cylinder head and gasket surfaces of cylinder block and al¡ timing chain covers . " Remove all foreign matter and any ¡¡quid from bolt holes, then clean with a thread chaser. CA UTIONDo not use a metal scraper or wire brush to clean the aluminum cylinder head or pistons. If necessary, use a hard wooden or plastic scraper. Also available are abrasive discs to be used in conjunction with an electric drill. Be sure to use the correct disc for the type of metal being cleaned.

2. Check gasket surface of cylinder head and cylinder block for warpage using a straight edge .

Fig. 40. Cylinder head bolt loosening sequence . NOTEBMW special tool no. 112250 is a thin-walled Torx E12 socket wíth an extended reach . The cylinder head bolts are recessed finto the head below the camshaft towers wíth liffle working space.

36 . Remove crankshaft locking tool (BMW special tool no . 11 2 300) . Using the crankshaft vibration damper bolt, turn engine opposite its normal direction of rotation (counterclockwise as viewed from the front) approximately 45°. This prevents accidental contact between valves and pistons during installation . NOTEGuide cam chain to keep it from jamming when turning the crankshaft.

Cylinder head, installing (6-cylinder engine) CAUTIONIf the camshafts were removed and installed while the cylinder head was off, a minimum waiting time is required after ínstalling the camshafts. When the camshafts are removed, the hydraullc lifters can expand. This expansion can cause increased valve lift when the camshafts are bolted down, resulting in open valves .

Cylinder head installation waiting times " 68°F (20°C) and higher . . . . . . . . . . . . . . . 10 minutes " 50-68°F (10-20°C) . . . . . . . . . . . . . . . . . . . 30 minutes " 32-50°F (0-10°C) . . . . . . . . . . . . . . . . . . . . 75 minutes

NOTEIf the cylinder head has been machined, a special 0.3 mm thickergasketshould be installed. The thickergasket is available from an authorized BMW dealer.

3. Place new cylinder head gasket on cylinder block . Checkthat two locating dowels are correctly positioned in block and are not damaged. NOTEThe word "OBEN", printed on the gasket, should face up.Thecylinderheadgasketwillfitcorrectlyinonlyone orientation.

4. With camshafts locked in TDC position with BMW special tools as described earlier, set cylinder head in po sition, guiding primary chain through cylinder head opening. CA UTION" The camshafts must be locked in the MC position at the rear of the cylinder head with BMW special tool no . 113 240 before installing the cylinder head. " Make sure the crankshaft, which had been rotated approximately 45° opposite the direction of engine rotation, is still in that position before lowering the cylinder head into position .

5. Lightly lubricate new cylinder head bolts. Loosely instan bolts and their washers, then thread them in until they are finger tight. Install cylinder head-to-lower timing chain cover boits finger tight. CAUTIONTonc-type cylinder head bolts should not be reused. They are stretch-type bolts and must always be replaced whenever loosened.

CYLINDER HEAD, 6-CYLINDER

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CYLINDER HEAD REMOVAL AND INSTALLATION

NOTECheck that all washers for the cylinder head bolts are in place before installlng the bolts. Some of the washers may be staked to the cylinder head.

6. Tighten cylinder head bolts in correct sequence. See Fig. 41 .

7. Install and tighten cylinder head-to-lower timing chain cover bolts. Tightening Torques " Cylinder head to engine block (Torx El 2 Ml 0 bolts) Stage 1 . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft-Ib) Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +90° Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .+90° " Cylinder head lo lower timing chain cover . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) 8. Carefully rotate crankshaft in direction of engine rotation and lock it at TDC by inserting BMW special tool no. 11 2 300 through transmission bellhousing . Guide primary timing chain to keep it from jamming on crank gear. 9. Mount primary chain sprocket to primary chain so that arrow on sprocket faces up. Mount sprocket to exhaust camshaft so tapped holes in camshaft are on left most side of elongated holes in sprocket . See Fig. 43 .

Fig. 41 . Cylinder head bolt tightening sequence for M50 engine .

Fig. 43 . Primary chain sprocket correctly afgned to exhaust camshaft. Camshaft holes should be on left most side of sprocket holes. 10 . Install timing chain guide and secondary chain tensioner . Tighten mounting bolts. Fig. 42. Protractor and pointer being used to tighten bolts to specified torque angle. WARNING The bolts should be tightened in three stages as listed below. The final stages require the use of a special tool (BMW tool No . 11 2 110) or a suitable protractor to tighten the bolts to a specified torque angle . See Fig. 42.

11 . Install as an assembly, secondary chain sprockets and chain so that arrow(s) on sprockt(s) are pointing up . Center mounting holes in sprockets to bolt holes in camshafts. See Fig. 44 . 12 . Install thrust washers and spring plate (if applicable) to sprockets. See Fig. 45 .

CYLINDER HEAD, 6-CYLINDER

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

CYLINDER HEAD REMOVAL AND INSTALLATION

113-17

14 . Insta¡¡ BMW special tool no. 11 3 390 into primary timing chain tensioner sleeve . Thread tool in finger tight until siack is removed from chain . NOTEBMW special tool no . 11 3 390 is a dummy primary chain tensioner and simulates the function of the tensioner. 15 . Insta¡¡ VANOS unit as described in 117 Camshaft Timing Chain . CAUTIONSpecial ínstallation instructions apply when mounting the VANOS unit to the cylinder head. Be sure to follow the procedure found in 117 Camshaft Timing Chain . 16 . Slowly uniock and release secondary chain tensioner. Fig . 44 . Secondary chain sprockets and chain being installed . Attach sprockets with arrows pointing up and elongated holes centered .

17 . Preload primary chain by tightening BMW special tool no. 11 3 390 (dummy chain tensioner) to 1 .3 Nm (11 inlb) . Then tighten exhaust secondary camshaft sprocket mounting bolts in two stages .

Tightening Torque

" Secondary timing chain sprocket to exhaust camshaft (Torx bolts) Stage 1 . . . . . . . . . . . . . . . . . . . . . . 5 Nm (44 in-lb) Stage 2 . . . . . . ,. . . . . . . . . . . . . . . . 22 Nm (17 ft-1b) 18 . Remove flywheel locking tool from transmission bellhousing . Remove camshaft locking tool from rear of cylinder head .

Spring plate

0012543

Fig. 45 . VANOS spring plate and thrust washers on later engines . CAUTIONMountintake camshaft sprocket so thatcollar side of the sprocket faces camshaft. 13 . Install and tighten exhaust camshaft sprocket mounting boits finger tight only. Tighten intake camshaft sprocket mounting nuts to specified torque .

Tightening Torque " Intake camshaft sprocket mounting nuts (M6) . . . . . . . . . . . . . . 10 Nm (89 in-lb)

19 . Turn engine over by hand at least two fui¡ crankshaft rotations . Reinstall camshaft locking tool and flywheel locking tool to make sure al¡ adjustments are still correct . lf settings are correct, remove locking tools . 20 . Remove BMW special tool 11 3 390 (dummy chain tensioner) from side of cylinder head . 21 . Insta¡¡ primary chain tensioner so that cutout in tensioner piston engages chain rail . See Fig . 46 . Using'new seals, install and tighten access plugs in VANOS con trol unit .

Tightening Torques " Access plugs to VANOS control unit . . . . . . . . . . . . . 50 Nm (37 ft-Ib) " Primary camshaft timing chain tensioner to tensioner sleeve . . . . . . . . . . . . . . . 50 Nm (37 ft-Ib)

CYLINDER HEAD, 6-CYLINDER

113- 1 8

CYLINDER HEAD REMOVAL AND INSTALLATION 24 . Installation of remaining parts is reverse of removal. Refill cooling system as described in 170 Radiator and Cooling System . Change engine oil and filter as de scribed in 020 Maintenance Program . Check adjustment of accelerator cable. Additional tightening torques are given below. Reconnect battery last . 25 . Installation of remaining parts is reverse of removal, noting the following:

Fig. 46 . Primary chain tensioner being installed . Piston cutout must engage chain rail . 22 . Install intake cam cover and then install cylinder head cover. Check for correct seating of half-moons in back of cylinder head cover. Use a small amount of 3-BondO 1209 or equivalent seaiant at corners of half-moon cutouts . Tightening Torque " Cylinder head cover to cylinder head(M6 screws) . . . . . . . 10 Nm (89 in-lb) 23. Install front exhaust pipes to manifolds using new gaskets and nuts . Coat manifold studs with copper paste prior to installing nuts .

CYLINDER HEAD, 6-CYLINDER

" Make sure all sealing surfaces are clean and free of old gasket material . Insta¡¡ new intake manifold gasket . " Reinstall harness connectors for oil pressure switch and coolant temperature sensor before installing intake manifold . " Refill cooling system as described in 170 Radiator and Cooling System . " Change engine oil and filter as described in 020 Maintenance Program . " If necessary, adjust accelerator cable. " Reconnect battery last . CAUTION-

To prevent damaging engine electronic systems, be sure to install all ground wires previously removed, including the ground wires at the cylinder head for the ignition coils .

Tightening Torques " Coglant drain plug to cylinder block . . 25 Nm (18 ft-Ib) " Intake manifold to cylinder head . . . . . 15 Nm (11 ft-Ib) " Radiator cooling fan to coolant pump . 40 Nm (30 ft-Ib) " Radiator drain screw to radiator . . . 2.5 Nm (22 in-lb)

CYLINDER HEAD AND VALVETRAIN

116-1

116 Cylinder Head and Valvetrai n GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116-1 CYLINDER HEAD, DISASSEMBLY AND ASSEMBLY . . . . . . . 116-1

Camshafts, removing and installing (M42 engine) . . . . . . . . . . . . . . . . . . . . . . . . . 116-1 Camshafts, removing and installing (M44 engine) . . . . . . . . . . . . . . . . . . . . . . . . . 116-3 Camshafts, removing and installing (6-cylinder engine) . . . . . . . . . . . . . . . . . . . . . 116-4 Valves, removing and installing . . . . . . . . . . . . . 116-6

CYLINDER HEAD AND VALVETRAIN, RECONDITIONING . . . . . . . . . . . . . . . . . . . . 116-7 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . 116-7 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116-7 Hydraulic valve adjusters, checking and replacing (M44 engine) . . . . . 116-8

GENERAL This repair group covers cylinder head and valvetrain service and repair. Most of the repairs described here require that the cylinder head first be removed as described in 113 Cylinder Head Removal and Installation . NOTE" For timing chain and VANOS repair information, see

117 Camshaft Timing Chain .

" If it is determined that the cylinder head will require significant reconditioning work, a remanufactured cylinder head may be a good alternative . Remanufactured cylinder heads are available from an authorized BMW dealer.

The information given in this repair group is organized according to engine code . For engine application information, see 100 Engine-General .

CYLINDER HEAD, DISASSEMBLY AND ASSEMBLY BMW special tools are required for most cylinder head service described in this repair group. Many of these tools are expensive and only available through an authorized BMW dealer. If the special tools are not available, one altematve is to remove the cylinder head and have it disassembled by an authorized BMWdealer . Be sure to read each procedure thoroughly before starting a job to determine which special tools and equipment will be necessary.

Hydraulic cam followers, checking and replacing (M42 and al¡ 6-cylinder engines) . . . . . . . . . . . . 116-9 Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . 116-10 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116-11 Valves, leak test . . . . . . . . . . . . . . . . . . . . . . . 116-11 Valve stem oil seals . . . . . . . . . . . . . . . . . . . . 116-11 Valve seats . . . . . . . . . . . . . . . . . . . . . . . . . .116-12 Valve springs . . . . . . . . . . . . . . . . . . . . . . . . . 116-12 TABLES a. Cylinder Head Height . . . . . . . . . . . . . . . . . . .. . . . . . 116-7 b. Camshaft Specifications . . . . . . . . . . . . . . . . . . . . .116-7 c. Valve Guide Specifications . . . . . . . . . . . . . . . . . . 116-10 d. Valve Specifications . . . . . . . . . . . . . . . . . . . . . . . . 116-11 e. Valve Seat Dimensions . . . . . . . . . . . . . . . . . . . . .116-12

Camshafts, removing and installing (M42 engine) The camshafts can be removed with the cylinder head mounted on the engine . The firststep is to remove the cylinder head cover. See 113 Cylinder Head Removal and Installation . Special BMW service tools should always be used to remove and install the camshafts. Removal and installation of the camshafts without the special tools can result in camshaft and valve train damage . WARNINGThe process of evenly loosening the camshaft bear ing cap nuts is NOT an acceptable method of removing the camshafts . Be sure to read the procedure through before starting the¡ob.

1 . Disconnect negative (-) battery cable. CAUTIONPrior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

2. Remove radiator cooling fan shroud and cooling fan. See 170 Radiator and Cooling System . CAUTIONRadiator fa n has left hand threads.

CYLINDER HEAD, DISASSEMBLYAND ASSEMBLY

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

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CYLINDER HEAD AND VALVETRAIN

3. Remove timing chain sprockets and timing chains from camshafts. Remove upper timing chain guide from cylinder head . See 117 Camshaft Timing Chain. NOTEIt is not necessary lo remove the lower timing chain cover.

4. Remove spark plugs and instaf BMW special tool 11 3 260 to cylinder head . Tighten tool retaining bolts in spark plug holes. Do not over-tighten bolts. See Fig. 1 .

7. Slowly release pressure on camshaft bearing caps by turning eccentric shaft. Remove bearing caps and camshaft . Repeat procedure on remaining camshaft. CAUTION-

Camshaft bearing caps must be reinstalled in their original locations.

NOTE" The camshaft bearing caps are coded wíth a letter anda number. For example, "Al "ís the exhaust camshaft bearing cap at the front of the engíne, and "El" is the intake camshaft bearing cap at the front of the engine . " Camshafts are stamped with a code letter-`E" for the intake side and `A" for the exhaust side. " "E" is for Einlal3, (German for íntake) and A" is for Auspuff, (German for exhaust). " The front of the engine is at the front of the car.

0013033

Fig. 1 . Special BMW tool no. 11 3 260. Tool mounting bolts (arrows) thread into spark plug holes. Tightening Torque " BMW special tool 11 1 260 to cylinder head . . . . . . . . . . . . . . . . . 23 Nm (17 ft-Ib) 5. Turn eccentric shaft on special tool until pressure is applied to camshaft bearing caps. See Fig. 2.

Fig. 2. Special tool (eccentric shaft) being turned to apply pressure to camshaft bearing caps . 6. Remove bearing cap mounting nuts .

CYLINDER HEAD, DISASSEMBLYAND ASSEMBLY

8. Camshaft installation is reverse of removal, noting the following: " Prior to installation, check al¡ components for wear as described below under Cylinder Head and Va¡vetrain, Reconditioning . " Crankshaft must be at least 45° away from TDC before installing camshafts to cylinder head . " Lubricate camshafts prior to installation . " Install camshafts into cylinder head with lobes for cylinder no . 1 pointing up and towards each other. " After installing camshafts), observe specified waiting time for hydraulic cam followers to fully compress before bringing crankshaft back to TDC.

CYLINDER HEAD AND VALVETRAIN Camshaft installation waíting times " At or above 68°F (20°C) . . . . . . . . . . . . . . . 10 minutes " 50-68°F (10-20°C) . . . . . . . . . . . . . . . . . . . 30 minutes " 32-50°F (0-10°C) . . . . . . . . . . . . . . . . . . . . . 75 minutes " Reinstall timing chain sprockets and tensioner as specifically described in 117 Camshaft Timing Chain . " Wait at least 10 minutes before cranking engine over with starter motor for the fi+ time .

Tightening Torques " Camshaft bearing caps to cylinder head (M7) . . . . . . . . . . . . . 15 Nm (11 ft-Ib) " Cylinder head cover to cylinder head (M6) . . . . . . . . . . . . . 10 Nm (89 in-lb) " Primary timing chain tensioner plug to cylinder head . . . . . . . . . . . . . . . . . 40 Nm (30 ft-Ib) (see 117 Camshaft Timing Chain) " Spark plugs (M12) . . . . . . . . . . . . . . . . 23 Nm (17 ft-Ib " Timing chain cover (upper) to cylinder head . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) " Timing chain sprockets to camshaft M6 . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (7 .5 ft-Ib) M7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 ft .lb) (see 117 Camshaft Timing Chain)

Camshafts, removing and installing (M44 engine) The camshafts can be removed with the cylinder head mounted on the engine . The first step is to remove the cylinder head cover. See 113 Cylinder Head Removal and Installation . Special BMW service tools should always be used to remove and install the camshafts. Removal and installation of the camshafts without the special tools can result in camshaft and valvetrain damage . WARNINGThe process of evenly loosening the camshaft bearing cap nuts is NOT an acceptable method of removing the camshafts. Be sure to read the procedure through before starting the job.

1 . Disconnect negative (-) battery cable.

116-3

2. Remove spark plugs. See 1201gnition System . 3. Rotate engine until a pair of camshaft lobes are pointing up . Using BMW special tool 115 130, depress each valve and valve spring enough to remove rocker arms . Rotate engine for the next pair of rocker arms . See Fig . 3. i

1/ /~~

Fig. 3. BMW special tool no . 11 5130 (arrow) being used to depress valve stem to remove rocker arm. WARNING Removed rocker arms must be reinstalled in the same locations.

4. Remove primary timing chain tensioner from right side of cylinder head . 5. Remove upper timing chain cover. NOTElt is not necessary to remove the lower timing chain cover.

6. Remove timing chain sprockets with timing chains from front of camshafts. See 117 Camshaft Timing Chain. Remove upper timing chain guide from cylinder head . 7. Remove camshaft bearing caes and remove cam shafts . CAUTIONCamshaft bearing caps must be reinstalled in their original locations.

CAUTIONPrior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡.

CYLINDER HEAD, DISASSEMBLYAND ASSEMBLY

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CYLINDER HEAD AND VALVETRAIN

NOTE" The camshaft bearing caps are coded with a letter anda number. Forexample, '541"is the exhaustcamshaft bearing cap at the front of the engine, and `El" is the intake camshaft bearing cap at the front of the engine. " Camshafts are stamped with a code letter-'E" for the intake side and A" for the exhaust side . " "E" is for Einla3, (German for intake) and A" is for Auspuff, (Germen for exhaust) . " The front of the engine is at the front of the car.

8. Camshaft installation is reverse of removal, noting the following: " Prior to installation, check all components for wear as described below under Cylinder Head and Valvetrain Reconditioning . " Lubricate camshafts prior to installation . " Reinstall timing chain sprockets and tensioner and set valve timing before reinstalling rocker arms, as specifically described in 117 Camshaft Timing Chain . " Be sure corresponding camshaft lobe is pointing up before installing rocker arms. Note that each rocker arm angles away from corresponding spark plug hole. See Fig. 4. " Wait at least 10 minutes for hydraulic cam followers to fully compress before cranking engine over with starter for the first time.

Tightening Torques " Camshaft bearing caps to cylinder head (M7) . . . . . . . . . . . . . 15 Nm (11 ft-Ib) " Cylinder head cover to cylinder head (M6) . . . . . . . . . . . . . 10 Nm (89 in-lb) " Primary timing chain tensioner plug to cylinder head . . . . . . . . . . . . . . . . . 40 Nm (30 ft-lb) (sea 117 Camshaft Timing Chain) " Spark plugs (M12) . . . . . . . . . . . . . . . . 23 Nm (17 ft-lb Timing chain cover (upper) to cylinder head M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (7 .5 ft-Ib) M7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 ft-Ib) " Timing chain sprockets to camshaft M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (7 .5 ft-Ib) M7 . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Nm (11 ft .lb) (sea 117 Camshaft Timing Chain)

Camshafts, removing and installing (6-cylinder engine) Camshafts on 6-cylinder engines can be removed with the cylinder head mounted on the engine . The first step is to remove the cylinder head cover. See 113 Cylinder Head Removal and Installation .

CYLINDER HEAD, DISASSEMBLYAND ASSEMBLY

516

Fig. 4. Correct installation position of rocker arms (arrows) on M44 engine . Special BMW service tools should always be used to remove and instan the camshafts. Removal of camshafts without the special tools can result in personal injury and/or cylinder head damage . WARNING The process of evenly loosening the camshaft bearing cap nuts is NOT en acceptable method of removing the camshafts. Special tools should always be used lo remove the camshafts. Be sure to read the procedure through before starting a job.

1 . Disconnect negative (-) battery cable. CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on paga viii.

2. Set engine to TDC and lock into position by installing BMW special tool 11 2 300 through transmission bellhousing and into hole in flywheel or drive platea See Fig. 5. NOTEArrows on camshaft sprockets should be pointing up. Sea 117 Camshaft Timing Chain.

3. Remove VANOS control unit from cylinder head . Remove timing chain sprockets from camshafts. See 117 Camshaft Timing Chain. 4. Remove spark plugs and insta¡¡ BMW special tool 11 3 260/11 3 270 to cylinder head . Tighten tool retaining bolts in spark plug holes. Do not ovar-tighten bolts. See Fig. 6.

CYLINDER HEAD AND VALVETRAIN

116-5

Fig. 7. Special tool (eccentric shaft) being turned to apply pressure to camshaft bearing caps . Fig. 5. BMW special tool 11 2 300 (arrow) inserted through bellhousing hole and finto flywheel .

8. Slowly release pressure on camshaft bearing caps by turning eccentric shaft. Remove bearing caps and camshaft . Repeat procedure on remaining camshaft. CAUTIONCamshaft bearing caps must be reinstalled in their original locations .

F19.6 . Special BMW tool no . 11 3 260 (A) with adapter l l 3 270 (B). Tool mounting bolts (arrows) thread into spark plug holes. Tightening Torque " BMW special tool 11 1 260/11 3 270 to cylinder head . . . . . . . . . . . . . . . . . 23 Nm (17 ft-Ib)

NOTE" The camshaft bearing caps are coded with a letter and a number. For example, À 1 "is the exhaust camshaft bearing cap at the front of the engine, and "E1" is the intake camshaft bearing cap at the front of the engine. " The camshafts are stamped with a code letter-È" for the intake síde and À" for the exhaust side .

" "E" is for Einfal3, (German for intake) and `A" is for Auspuff, (German for exhaust) .

" The front of the engine is at the front of the car.

5. Remove intake camshaft bearing cap no. 1 . 6 . Turn eccentric shaft on special tool until pressure is applied to camshaft bearing caps . See Fig. 7. 7 . Remove remaining bearing cap mounting nuts .

CYLINDER HEAD, DISASSEMBLYAND ASSEMBLY

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CYLINDER HEAD AND VALVETRAIN

9. Camshaft installation is reverse of removal, noting the following: " Prior to installation, check al¡ components for wear as described below under Cylinder Head and Valvetrain Reconditioning . " Crankshaft must be at least 45° away from MC before installing camshafts to cylinder head . " Lubricate camshafts prior to installation . " Insta¡¡ camshafts into cylinder head with lobes for cylinder no. 1 pointing up and towards each other. See Fig. 8. " After installing camshaft(s), observe specified waiting time for hydraulic cam followers to fully compress before bringing crankshaft back to TDC.

Camshaft installation waiting times " at or above 68°F (200C) . . . . . . . . . . . . . . . 10 minutes " 50-68°F (10-20°C) . . . . . . . . . . . . . . . . . . . 30 minutes " 32-50°F (0-10°C) . . . . . . . . . . . . . . . . . . . . 75 minutes " Reinstall timing chain sprockets and tensioner as specifically described in 117 Camshaft Timing Chain. " Waít at least 10 minutes before cranking engine over with starter motor for the first time .

Valves, removing and installing 1 . Remove cylinder head as described in 113 Cylinder Head Removal and Installation . Remove exhaust manifold(s) . 2. Remove camshafts using special tools as descríbed earlier. 3. On M42 and al¡ 6-cylinder engines: Remove camshaft carriers by pulling them straight up off mounting studs. CAUTION" Do not let the hydraulic cam followers fa¡¡ out as the camshaft carrier is removed. Special suction cups are available from BMW to hold the hydraulic cam followers in place during carrier removal. " Hydraulic cam followers should be stored in an upright position .

4. On M44 engines: Remove all hydraulic valve adjusters. See Hydraulic valve adjusters, checking and replacing (M44 engine), later in this section. CAUTIONHydraulic valve adjusters should be stored in an upright position . lf necessary, use a magnetic tool to aid in removal of the adjusters.

5. Remove valves using a valve spring compressor. NOTE" The M44 cylinder head has recessed valve stems. This requires the use of a special valve spring compressor tool. " Label each valve assembly as it is removed so it can be installed in its original position.

6. Remove and discard valve stem oil seals from valve guides . See Valve stem oil seals later in this section. Fig . 8. Camshaft correctly positioned for reassembly so that cylinder no . 1 lobes (arrows) face each other.

7. Valve installation is reverse of removal.

" Reinstall exhaust manifold(s) with new gaskets. Use Molycote HSC' 5 or equivalent anti-seize thread compound on fasteners.

Tightening Torque " Exhaust manifold to cylinder head M7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (15 ft-Ib)

CYLINDER HEAD, DISASSEMBLYAND ASSEMBLY

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116-7

CYLINDER HEAD AND VALVETRAIN, RECONDITIONING Thís section provides the specifications and special reconditioning information necessary to repair the cylinder heads covered by this manual . If machine shop services are not readily available, one alternative is to install a remanufactured cylinder head from an authorized BMW dealer.

Cylinder head The disassembled cylinder head should be inspected for warpage and cracks . Checkthe valve guides and valve seats for wear before machining a warped head . Always decarbonize and clean the head before inspectiog it . A high-quality straíght edge can be used to check for warpage. Visually inspect the cylinder head for cracks . If a cracked cylinder head is suspected and no cracks are detected through the visual inspection, have the head further tested for cracks by an authorized BMW dealer . A cracked cylinder head must be replaced . NOTEWhen replacing the cylinder head on engines with removable camshaft carriers, be sure to check the camshaft carrier bearing surfaces for warpage.

A warped cylinder head can be machined provided no more than 0.3 mm (0 .012 in) of material is removed. If further machining is required, the head should be replaced . Removing more than this amount will reduce the size of the combustion chamber and adversely affect engine performance. A 0.3 mm thicker gasket is available from an authorized BMW parts department for machined heads. Before machining the head to correct forwarpage, measure the total height (thickness of the cylinder head). See Fig . 9. Minimum height specifications are given in Table a. Table a. Cylinder Head Height Engine

New

Minimum height (dimension A)

Fig. 9. Front víew of cylinder head showing minimum resurfacing dimension (A).

Camshaft Camshaft wear is usually caused by insufficient lubrication . Visually inspect the camshaft lobes and journals for wear. Camshaft wear specifications are given in Table b. Table b. Camshaft Specifications 4-cylinder engines Axial play M42 engine M44 engine Radial play (Plastigage) M42 engine M44 engine

0 .065-0.150 mm (0 .0025-0 .0059 in) 0 .065-0.150 mm (0 .0025-0 .0059 in) 0 .020-0.061 mm (0 .0008-0 .0024 in) 0 .040-0.082 mm (0 .0016-0 .0032 in)

6-cylinder engines Axial play 0 .020-0 .054 mm (0 .0008-0 .0021 in) All Radial play (Plastigage) 0 .150-0 .330 mm (0 .006-0 .013 in) All NOTE- On M44 engines, check the oil sprayer tube in the top of the cylinder head coverand the tube sea¡ in the cylinderhead.Acloggedsprayertubeoradefectiveseal will reduce oil flow to the camshaft. See Fig. 10. - If the camshaft is being replaced due to cam lobe wear, the corresponding rockerarms orcam followers shouId also be replaced to avofd damaglng the new camshaft.

1 140 .0 mm (5 .512 in) 1 139 .55 mm (5 .494 in) 6-cylinder 1 140 .0 mm (5 .512 in) 1 139 .7 mm (5 .500 in) 4-cylinder

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116-8

CYLINDER HEAD AND VALVETRAIN NOTE8efore checking valve adjusters, make sure engine oil is fresh and at proper level. 1 . Run engine until it reaches normal operating temperatu re. 2 . Turn engine off and remove top engine cover, spark plugs, and cylinder head cover. See 113 Cylinder Head Removal and Installation . 3 . Use a plastic or wooden stick to press down on top of rocker arm end (side away from camshaft) . If any play can be detected, the HVA is faulty and should be replaced . 0012502

Fig . 10 . Location of camshaft oil sprayer tube sea¡ in M44 cylinder head (arrow) .

Hydraulic valve adjusters, checking and replacing (M44 engine) The M44 engine uses hydraulic valve adjusters (HVA) to keep valve clearances within a limited working range . See Fig . 11 . HVAs are sealed units and require no maintenance .

NOTEWhen checking the HVA, make sure the camshaft lobe is facing up so that there is no valve spring pressure on the adjuster. 4 . To remove an HVA, turn engine over until camshaft lobe points straight up . Using BMW special tool no. 11 5 130, depress valve spring and remove rocker arm from under camshaft. See Fig . 12 .

1 . Camshafts 2 . Rocker arms 3 . Hydraulic valve adjusters (HVA) 4 . Valve and conical valve spring

Fig . 12. BMW special tool no . 115 130 (arrow) being used to depress valve stem to remove rocker arm .

Fig . 11 . Cutaway view of M44 cylinder head . Under some circumstances, such as a cold start, the hydraulic units may become noisy . Hydraulic valve adjuster noise is usually a high-pitched tapping or chattering noise . In most instances, this is consídered normal as long as the noise goes away in a few minutes (maximum 20 minutes) . If the noise does not go away, either the hydraulic unit is faulty or the oil pressure to the adjuster(s) is low . CYLINDER HEAD AND VALVETRAIN, RECONDITIONING

WARNING Removed rocker arms must be reinstalled in the same locations .

CYLINDER HEAD AND VALVETRAIN

116-9

5. Pull hydraulic valve adjuster straight out of cylinder head . See Fig . 13 .

Fig. 13 . Remove hydraulic valve adjuster by pulling straight out of cylinder head (arrow). 6. Installation is reverse of removal. Be sure to inspect HVA bore in the cylinder head for wear or scoring. Tightening Torque " Cylinder head cover to cylinder head/timing chain cover M6 bolt . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) M7 bolt . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 ft-Ib)

Fig. 14 . Section view of camshaft (A), hydraulic cam follower (B), and valve with conical valve spring (C) used on M52 engine . 1 . Run engine until it reaches normal operating temperature . 2. Turn engine off and remove top engine covers, ignition coils, and cylinder head covers . See 113 Cylinder Head Removal and Installation . 3. Use a plastic or wooden stick to press down on top of cam follower. See Fig. 15 . If there is any noticeable clearance, the follower is faulty and should be replaced .

Hydraulic cam followers, checking and replacing (M42 and al¡ 6-cylinder engines) The M42 engine and al¡ 6-cylinder engines use self-adjusting hydraulic cam followers to keep the valve clearances within a limited working range. The cam followers are sealed units and require no maintenance. See Fig . 14 .. Under some circumstances, such as a cold start, the cam followers may become noisy. Hydraulic cam follower noise is usually a high-pitched tapping or chattering noise. In most instances, this is considered normal as long as the noise goes away in a few minutes (maximum 20 minutes) . lf the noise does not go away, either the follower is faulty or the oil pressure to the follower is low. Hydraulic cam follower replacement requires that the camshaft first be removed. NOTEBefore checking valve adjusters, make sure engine oil ís fresh and at proper level.

811107

Fig. 15 . Hydraulic cam follower in M52 engine being checked. Note that camshaft lobe is pointing up .

CYLINDER HEAD AND VALVETRAIN, RECONDITIONING

116- 1 0

CYLINDER HEAD AND VALVETRAIN

NOTEWhen checking a cam follower, make sure the corresponding camshaft lobe ís facing up so that there is no valve spring pressure on the follower.

4. To replace a cam follower, remove appropriate camshaft. Refer to camshaft removal procedures given earlier. 5. Once camshaft is out of way, withdraw faulty cam follower and replace with new one. Inspect cam follower bores for wear and scoring. 6. Camshaft, timing chain and cylinder head cover reassembly is reverse of disassembly. Tightening Torques " Camshaft bearing caps to cylinder head M7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 ft-Ib) " Cylinder head cover to cylinder headltiming chain cover M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) " Timing chain hydraulic tensioner to cylinder head-see 117 Camshaft Timing Chain " Timing chain sprocket to camshaft flange (M6)-see 117 Camshaft Timing Chain

Valve guides BMW does not supply valve guides as replacement parts . If a valve guide is excessively worn, it should be reamed to accept oversized valve stems. Valve guide specifications are listed in Table c. Valve guides should be checked for wear using a new valve. See Fig. 16 . Be sure to thoroughly inspect the cylinder head to ensure that it can be reused before reworking the guides.

Fig. 16 . Valve guide wear being checked with dial indicator. Insert new valve until stem end is flush with end of guide (white arrow) . See Table c forwear limits . NOTE" Intemational Organization for Standardization (ASO) tolerance classes are Gsted in Table c. ISO allowanc es are based on nominal sizes and should be used to determine proper fit. Most machine shops should have thís information available

" Replacement valve guides may be available through

aftermarket suppliers. Valve guide replacement requires specíal tools and a press . It is also necessary to heat the cylinder head and chile the valve guides when replacing the guides.

" BMW supplles oversize valves. Sea Valves for additional information.

Table c. Valve Guide Specifications Specifications Valve guide wear, maximum (valve tílt clearance measured with new valve) Valve guide inside diameter, installed (tolerance per ISO allowance H7) Standard Oversize 1 Oversize 2

M42 engine

~ (1992)

M421M44 engines ~ (1993-1998)

M50 engine ~ (1992)

M50, M52, S50 US, S52 ~ US engines (1993-1998)

0 .5 mm (0 .020 in)

0 .5 mm (0.020 in)

0.5 mm (0 .020 in)

0 .5 mm (0 .020 in)

7 .0 mm (0 .276 in) 7 .1 mm (0 .279 in) 7 .2 mm (0 .283 in)

6 .0 mm (0 .236 in) 6 .1 mm (0 .240 in) 6 .2 mm (0 .244 in)

7.0 mm (0 .276 in) 7.1 mm (0 .279 in) 7.2 mm (0.283 in)

6 .0 mm (0 .236 in) 6 .1 mm (0 .240 in) 6 .2 mm (0 .244 in)

CYLINDER HEAD AND VALVETRAIN, RECONDITIONING

CYLINDER HEAD AND VALVETRAIN

116- 1 1

Valves Valve specifications are listed in Table d. Remove carbon deposits from the valves using a wire brush or wire wheel. Table d . Valve Specifications Specification

M42 engine (1992)

M42IM44 engines (1993-1998)

M50 engine (1992)

M50, M52 engines (1993-1998)

Valve head dia. Intake Exhaust

I engine (1995-1998)

133.0 mm (1 .299 in) 30 .5 mm (1 .201 in)

33.0 mm (1 .299 in) 30.5 mm (1 .201 in)

33 .0 mm (1 .299 in) ~ 30 .5 mm (1 .201 in)

130.0 mm (1 .181 in) 27 .0 mm (1 .063 in)

6.975-0 .015 mm (0.2746-00006 in) 6.960-0015 mm (0.2740-00006 in)

5.975-0.015 mm (0 .2352-00006 in) 5.960-0 .015 mm (0 .2345-0 .0006 in)

6.975-0 .015 mm (0 .2746-00006 in) 6.960 --0.015 mm (0 .2740--0.0006 in)

5.975-0 .015 mm (0 .2352-00006 in) 5.960 -0 .015 mm (0.2345-0 .0006 in)

5.975-0015 mm (0 .2352-00006 in) 5.960 -0 .015 mm (0 .2345-0 .0006 in)

7.075-0.015 mm (0.2785-00006 in) 7.060-0015 mm (0.2779-0 .0006 in)

6.075-0 .015 mm (0 .2392-0.0006 in) 6.060-0015 mm (0 .2386-00006 in)

7.075-0 .015 mm (0 .2785-00006 in) 7 .060-0 .015 mm (0.2779-00006 in)

6.075-0.015 mm (0 .2392-00006 in) 6.060-0015 mm (0 .2386-00006 in)

6.075-0 .015 mm (0 .2392-00006 in) 6.060-0015 mm (0 .2386-00006 in)

7.175-0.015 mm (0 .2825-00006 in) 7.160-0015 mm (0.2819-00006 in)

6 .175-0 .015 mm (0 .2431-00006 in) 6.160-0015 mm (0 .2425-00006 in)

7.175-0 .015 mm (0.2825-00006 in) 7.160-0.015 mm (0.2819-00006 in)

6.175-0 .015 mm (0 .2431--0 .0006 in) 6.160-0015 mm (0 .2425-00006 in)

6.175-0 .015 mm (0 .2431-00006 in) 6.160-0-015 mm (0 .2425-00006 in)

Valve stem dia. Standard Intake Exhaust Intake Exhaust Oversize 2 Intake Exhaust

Valves, leak test To test the valves for leakage, the camshafts and camshaft carriers (where applicable) should first be removed. Instali the valve assemblies and the spark plugs in each cylinder . Place the cylinder head on a workbench with the combustion chamber facing upward . Fill each combustion chamber with a thin non-flammable liquid, such as a parts cleaning fluid. After fifteen minutes, check the leve¡ of the fluid . If the fluid level in any cylinder drops, that cylinder is not sealing properly .

S50 USIS52 US

NOTEBMW speclal tools are available to remove the valve stem oil seals. As an alternative, standard valve sea¡ removal tools are available from most automotive parts stores . See Flg. 17.

Valve Stem Oil Seals The purpose of the valve stem oil sea¡ is to prevent excess oil from entering the combustion chamber. The sign of fautty valve stem oil seals is excessive oil consumption and smoke from the exhaust immediately after starting and during decelerat¡on NOTEValve stem oil seals should not be reused. ff valves are removed, new valve stem oil seals should be installed. Valve stem oil sea¡ replacement requires that the cylinder head be disassembled and the valves removed as described above under Valves, removing and installing .

Fig. 17 . Valve stem oil sea¡ being removed from valve guide. Lubricate the new seals and insta¡] them using hand pressure only. Be sure to install the valve spring seat(s) before installing the sea¡ .

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CYLINDER HEAD AND VALVETRAIN

Valve Seats

Valve Springs

The valve seats should be resurfaced whenever new valves or valve guides are installed. Cutters are required to resurface the seats. Always check the valves for leaks after reconditioning a valve seat as described above. Table e lists valve seat dimensions .

The valve springs should be checked for fatigue. To quickly check the springs, line them up in a row. Place a straight edge across the top of the springs. Any spring that is significantly shorter than the others is worn and should be replaced . NOTEValve spring specifications and wear límits are not available from BMW.

NOTEStandard size replacement valve seats are not available from BMW. Replacement valve seats are only available from BMW in 0.4 mm oversize (oversized in both height and diameter) . The manufacturer does not provide specífications for valve seat replacement for the engines covered by this manual.

Table e. Valve Seat Dimensions

60°

1 B11110c

Specification

M42 engine (1992)

M42 engine ( (1993-1995)

M44 engine I (1996-1998)

M50 engine (1992)

M501M52 engines S50USIS52US I (1993-1998) I engines (19951998)

Valve seat angle

45°

451

145°

( 45°

145°

Correction 1 15° angle, outside

15°

115°

( 15°

15°

Correction angle, inside

60°

I60°

60°

I60°

1 1 .65 ± 0 .25 mm (0.065 t 0 .014 in) I 12 .0 t 0 .25 mm 1 (0 .079 t 0 .014 in)

1 1 .65 t 0 .25 mm (0 .065 :E 0.014 in)

1 1 .4 - 1 .9 mm (0 .055-0 .075 in)

1 1 .65 ± 0 .25 mm (0 .065 t 0 .014 in)

1 1 .65 t 0 .25 mm 1 (0.065 ± 0 .014 in)

1 1 .4 - 1 .9 mm 1 (0 .055-0 .075 in)

11 .65 ± 0 .25 mm 1 (0 .065 t 0.014 in)

1 1 .65 ± 0.25 mm (0 .065t 0.014 in) l ____ _ __ 1 1 .65 :t 0.25 mm 1 (0.065 t 0 .014 in)

60°

Valve seat width (A) intake

1 1 .65 ± 0 .25 mm (0 .065 + 0.014 in)

exhaust

12 .0 ± 0.25 mm (0 .079 ± 0.014 in)

Valve seat outside dia . (B) intake

32.4 mm (1 .276 in)

32 .4 mm (1 .276 m)

32 .4 mm (1 .276 in)

29 .4 mm (1 .157 in)

exhaust

30.1 mm (1 .185 in)

30 .1 mm (1 .185 in)

29 .4 mm (1 .157 in)

26 .4 mm (1 .039 in)

CYLINDER HEAD AND VALVETRAIN, RECONDITIONING

CAMSHAFT TIMING CHAIN

117-1

117 Camshaft Timing Chain GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117-1 CAMSHAFT TIMING CHAIN, 4-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 117-2

Camshaft timing chain, removing (4-cylinder engines) . . . . . . . . . . . . . . . . . . . . . 117-2 Camshaft timing chain, installing (4-cylinder engines) . . . . . . . . . . . . . . . . . . . . 117-4

CAMSHAFT TIMING CHAINS, 6-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 117-6

GENERAL This repair group covers timing chain repair information for the 4- and 6-cylinder engines. 4-cylinder engines use one double-row chain to drive the dual overhead camshafts. See Fig. 1 .

Camshaft timing chains, removing (6-cylinder engines) . . . . . . . . . . . . . . . . . . . . .117-7 Camshaft timing chains, installing 6-cylinderengi nes 117-11 ( VANOS (VARIABLE VALVE TIMING) . . . 117-14 VANOS system operation, testing . . . . . . . . . . 117-14 VANOS control unit, removing . . . . . . . . . . . . . 117-16 VANOS control unit, installing . . . . . . . . . . . . . . 117-17

6-cylinder engines use two chains to drive the camshafts. A primary chain is driven off the crankshaft and drives the primary sprocket on the exhaust camshaft. The secondary chain drives the intake camshaft . Each chain is tensioned by a hydraulic tensioner. See Fig. 2. The timing chains are lubricated by engine oil and do not re-` quire maintenance. A worn timing chain and sprockets can lead to noisy operation and erratic valve timing . A faulty tensioner can also cause timing chaín noises .

Secondary chain tensioner Primary chain

Secondary chain

B11115

Fig. 2. Cutaway view of camshaft timing chains on 1963 and later 6cylinder engine with VANOS.

Fig. 1 . M44 engine valvetrain chain drive. M42 engine is similar.

NOTESee 100 Engine-General for engine code and application information .

GENERAL

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117-2

CAMSHAFT TIMING CHAIN

CAMSHAFT TIMING CHAIN, 4-CYLINDER Special BMW service tools are needed for timing chain removal and installation procedures . The special tools assure proper timing of the valvetrain . Precíse marks to set the timing on the camshafts are not provided for reassembly . Read the procedures through before beginning the job. CAUTIONlf the camshafts are not properly timed, the pistons can contact the valves.

Camshaft timing chain, removing (4-cylinder engines) 1 . Disconnect negative (-)cable from battery. CAUTIONPrior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii.

U0119-

Fig. 3. Upper timing chain cover mounting bolts (arrows) . Thermostat housing shown removed. Cylinder ídentification sensor (A) also shown. 7. Set engine to approximate TDC by rotating in normal operating direction until camshaft lobes at cylinder no . 1 are facing up and toward each other. See Fig. 4.

2. Drain engine coolant. Drain engine block by removing block drain. Remove radiator cooling fan shroud and cooling fan. See 170 Radiator and Cooling System .. WARNING Allow the engine to cool before opening or draining the cooling system. CA UTIONOn cars with viscous-type fan clutch, fan has left hand threads . NOTEThe block drain plug is located on the exhaust side of the engine, below cylinder no. 4.

3. Remove cylinder head cover. See 113 Cylinder Head Removal and Installation . NOTEMake note of the arrangement of the rubber insulators when removing the cylinder head cover mounting belts .

4. Loosen spark plugs. See 120 Ignition System . 5. Disconnect coolant hoses from thermostat housing on front of cylinder head . Unbolt thermostat housing from cylinder head . 6. Remove cylinder identification sensor from upper timing chain cover. Remove uppertiming chain cover. See Fig . 3. CAMSHAFT TIMING CHAIN, 4-CYLINDER

0011998

Fig. 4. Engine set to approximate TDC. Cylinder no . 1 camshaft lobes face in and sprocket arrows point up (arrows) . 8. Remove air conditioning drive belt . Loosen and push aside air conditioning compressor. Remove air conditioning compressor mounting bracket. See 640 Heating and Air Conditioning . 9. Remove engine drive belts and coolant pump pulley. See 020 Maintenance Program . 10 . Secure crankshaft vibration damper to prevent crankshaft from turning . Using a socket, loosen vibration damper hub center bolt .

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

CAMSHAFT TIMING CHAIN NOTEThe vibration damper center bolt is very tight. A heavy duty holding device, such as BMW special tool no. 112 150, should be used to hold the vibration damper hub stationary while the bolt is loosened.

11 . Using loosened bolt at vibration damper, turn crankshaft to TDC and lock in position by inserting BMW special tool no . 11 2 300 through transmission bellhousing. See Fig. 5. NOTE" If necessary, remove plug from locating boye in lower edge of bell housing. " Confirm that locatng tool has been correctly installed by trying to rotate the crankshaft.

Fig. 5. BMW special tool no . 11 2 300 installed through bellhousing and finto flywheel to lock crankshaft at TDC (arrow).

117- 3

0011966a

Fig. 6. BMW special tool no . 11 3 240 installed on rear of camshafts to position camshafts at TDC. (M44 camshafts shown. Other engines are similar.

Fig. 7. Lower timing chain cover mounting bolts (arrows) . Bolts A are installed through hollow locating dowels .

12 . Lock camshafts at TDC by mounting BMW special tool no . 113 240 over square ends of camshafts. See Fig. 6. " Check that tool is squarely seated on cylinder head gasket surface. If necessary, rotate camshafts slightly using an open-end wrench at hex on camshafts. CA UTIONThe camshafts must be locked in the MC position using the special service tool before removing the timing chain . The tool holds the camshafts parallel to each other and perpendicular to the valve cover gasket surface .

13 . Remove lower timing chain cover mounting bolts and carefully lift cover off. Clean sealing surfaces and gasket grooves. See Fig. 7. 14 . Remove hydraulic chain tensioner from right side of cylinder head. See Fig. 8.

Fig. 8. Hydraulic chain tensioner plug (arrow). CAMSHAFT TIMING CHAIN, 4-CYLINDER

117-4

CAMSHAFT TIMING CHAIN

15 . Remove mounting bolts from left and right camshaft sprockets.

16 . On M42 engines, remove upper bolt on right side chain guide and unbolt lower timing chain guide below crankshaft. 17 . Remove camshaft sprockets from camshafts together with chain and crankshaft sprocket . Note Woodruff key when removing crankshaft sprocket.

4. Insta¡¡ and hand-tighten sprocket mounting bolts. 5. On M42 engine : Install lower chain guide. 6. On M44 engine : Remove allen-head retaining screw at left chain-guide . Turn slotted-head of adjusting sleeve so that sleeve contacts cylinder head . Then install and tighten'allen-head screw fully. See Fig. 10 .

CA UTIONThe crankshaft must not be allowed to rotate when the timing chaín is removed. The pistons can contact the valves .

Camshaft timing chain, installing (4-cylinder engines) Inspectal¡ sprockets for wear or damage . Inspect the chain guide and tensioner rails for grooves caused by chain contact. Replace any part that is worn . If any of the sprockets are worn, the chain and sprockets are replaced as an assembly. The procedure outlined below assumes that the camshafts and the crankshaft are locked in the TDC installation position with special tools (shown earlier in Fig. 5 and Fig. 6) . 1 . Install timing chain to crankshaft sprocket, then slide sprocket on crankshaft whíle aligníng woodruff key. 2. Place camshaft sprockets on chain, then place sprockets on camshafts so that arrows on sprockets point up and elongated holes in sprockets are centered lo tapped holes in camshafts. See Fig. 9.

CAUTIONDifferent hydraulic chain tensioners were used during manufacture, depending on engíne type. See Fig. 11 . Note that the late style tensioner can be retrofitted to the earlier engíne, so be sure to identify the versíon of tensioner ínstalled as ínstallation instructions vary between the two.

.I P

Ge.. .

7. On M42 engine : Disassemble chain tensioner by striking outer sleeve against a solid object . This will release snap ring and tensioner will separate . See Fig. 12 .

0012509

Fig . 9 . Camshaft sprockets correctly installed with arrows pointing up and bores centered to tapped holes (M44 engine) .

3. On M44 engine : Place cylinder position sensor plate on intake camshaft sprocket so that arrow on sensor plate points up . CAMSHAFT TIMING CHAIN, 4-CYLINDER

Fig . 10 . Left upper chain guide adjusting sleeve (arrow) . Note camshaft position

8. On M42 engine : Clamp chain tensioner piston in vice (soft jaws). Slowly compress piston, making sure detent ring fits into taper of outer sleeve. If necessary, press ends of detent ring together. Slowly continue pressing tensioner together until snap ring audibly clicks into outer sleeve . Measure overall length of tensioner to confirm correct assembly : 68 .5 mm (2 .7 in .) . NOTEThe ¡ate-style tensioner on the M44 engine can be retrofitted to the M42 engíne.

CAMSHAFT TIMING CHAIN

117-5

M42 Engine

CL (EM

0013024a

Fig. 11 . Two versions of hydraulic chain tensioners . Original chain tensioner on M42 engine (top) can be disassembled . Chain tensioner on M44 engine (bottom) cannot be disassembled . Note differences in outer sleeve . Also, the M42 tensioner detent ring groove is visible when tensioner is extended (arrow) .

0012507

Fig. 13 . When reinstalling chain tensiones, oil in tensioner piston must first be expelled by compressing piston in vise . When compressing piston, only compress up to and circlip (arrow) .

Tightening Torque " Chain sprocket lo camshaft flange (M6) . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) 13 . Remove crankshaft locking tool from bellhousing and camshaft locking tool from rear of cylinder head . Detent ring

Outer sleeve Spring

Snap ring

0013024

Fig . 12 . Disassembled early-style chain tensioner usad on M42 engine .

14 . Install lower timing chain cover : " Insta¡¡ new crankshaft oil seal in cover. " Use new gaskets when installing cover. " Thoroughly clean profile gasket groove and all gasket sealing surfaces on lower chain cover . " Apply a small bead of silicon sealer (3-Bond 1209 or equivalent) lo joint corners where chain cover meets head and block. See Fig . 14. " Tap cover into position to engage locating dowels. " Tighten cover mounting bolts alternately and in stages .

9 . On M44 engines : Clamp tensioner piston in vice (soft jaws) and squeeze oil from it . Slowly compress piston only up to end círclip . Repeat procedure twice to ensure al¡ oil is expelled . See Fig . 13. 10 . Insta¡¡ hydraulic chain tensioner lo cylinder head . Use a new sealing washer on tensioner plug when installing . Tightening Torque " Chain tensioner to cylinder head . . . . 40 Nm (30 ft-Ib) 11 . On M42 engines : Release early-style chain tensioner by pressing chain guide against tensioner until it unlocks and expands out. 12 . Check that chain is now free of siack. Tighten down sprocket mounting bolts .

Fig . 14. Apply sealer (3-Bond 12090 or equivalent) to joint corners where chain cover meets head and block (arrows) . CAMSHAFT TIMING CHAIN, 4-CYLINDER

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15 . Insta¡¡ upper timing chain cover: " Thoroughly clean profile gasket groove and all sealing surfaces . " Apply a small bead of silicon sealer (3-Bond 1209® or equivalent) to upper and lower joint comers where chain cover meets cylinder head. " Insta¡¡ new profile gasket to groove in lower chain cover. " Protect top of profile gasket using thin sheet metal (BMW special tool no . 11 2 330 or equivalent) . See Fig. 15 . " Attach new gaskets to cover with light dabs of gasket sealant, hold gaskets in place using cover mounting screws . " Place upper timing cover into position . Snug down al¡ screws, without tightening . Carefully slide out sheet metal . " Temporarily install cylinder head coverwithout gasket . Insta¡¡ and tighten at least two cylinder head cover mounting bolts to seat upper timing chain cover. " Tighten all upper timing cover screws. " Remove valve cover.

17 . Remove crankshaft locking tool from transmission bellhousing and camshaft locking tool from rear of cylinder head . 18 . Turn engine over by hand in direction of rotation at least two full rotations. Reinstall camshaft and crankshaft locking tools to check engine timing . Repeat cam timing procedure if tools do not fit easily into position . Remove locking tools. 19 . Install cylinder head cover as described in 113 Cylinder Head Removal and Installation . NOTEOn M44 engines, note oil supply O-ring and replace ff necessary.

Tightening Torque " Cylinder head cover to cylinder head (M6 screws). . . . . . . 10 Nm (89 ín-Ib) 20 . Installation of remaining parts is reverse of removal. When installing thermostat, make sure arrow or vent hole faces up . Refill cooling system as described in 170 Radiator and Cooling System . Tighteníng Torques " Coolant drain plug to cylinder block . . . . . . . . . . . . . . . . . 25 Nm (18 ft-Ib) " Radiator cooling fan to coolant pump . . . . . . . . . . . . . . . . . 40 Nm (30 ft-Ib) " Radiator drain screw to radiator . . . . 2 .5 Nm (22 in-lb)

Fig. 15. When installing uppertiming chain cover, use thin sheet metal (arrow) to protect profile gasket when installing upper cover. Tightening Torque " Upper timing chain cover to engine block or cylinder head (M6 screws) . . . . . . . 10 Nm (89 in-lb) 16. Install vibration damper while aligning woodruff key. Hold crankshaft stationary and tighten mounting bolt . Tightening Torques " Pulley to vibration damper . . . . . . . . . 22 Nm (17 ft-Ib) " Vibration damper to crankshaft M16 stretch bolt (always replace) . 330 Nm (244 ft-Ib)

CAMSHAFT TIMING CHAINS, 6-CYLINDER

CAMSHAFT TIMING CHAINS, 6-CYLINDER Camshaft timing chain removal on 6-cylinder engines requires that you Rmove the engine oil pan by raising the engine and/or lowering the front suspension crossmember. Special BMW service tools are needed for timing chain removal and installation procedures . The special tools assure proper timing of the valvetrain . Precise marks to set the timing on the camshafts are not provided for reassembly. Read the procedures through before beginning the job.

I CAUTION-

lf the camshafts are not properly timed, the pis1 tons can contact the valves.

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Camshaft timing chains, removing (6-cylinder engines) 1 . Disconnect negative (-) cable from battery. CA UTIONDisconnecting the battery may erase fault codes) stored in control module memory. Check for fault codes using special BMW diagnostic equipment.

Fig. 16 . Drive belt tensioner mounting bolts (arrows) .

CAUTIONRadiator fan has left hand threads . NOTEThe block drain plug is located on the exhaust side of the engine, below cylinder no. 4 .

3. Drain engine oíl and remove oil pan. See 119 Lubrication System . 4. Remove alternator cooling duct . 5. Remove two large coolant hoses from thermostat housing. Remove engine lifting bracket and thermostat housing from front of cylinder head . 6. Loosen bolts for coolant pump pulley. Then remove drive belts for alternator and A/C compressor. See 020 Maintenance Program. Remove coolant pump pulley. 7. Remove drive belt tensioner from front of engine . See Fig. 16 . NOTEOn M50 engines with a two-roller drive belt tensioner, remove the upper roller to access the tensioner mounting bolts.

8. Remove engine speed sensor from lower timing chain cover, if applicable . See Fig. 17 . 9. Remove cylinder head cover. See 113 Cylinder Head Removal and Installatíon . NOTEMake note of the arrangement of the rubber insulators when removing the cylinder head cover mounting bolts .

B11055

Fig. 17 . 1992-1995 M50 engine speed sensor on timing cover (arrow) . 10 . Unclip and remove baffle cover from above intake camshaft. See Fig. 18 . 11 . On 1992 engines: Remove upper timing chain cover from front of cylinder head . See Fig. 19 . 12 . Loosen spark plugs. See 120 Ignition System . 13 . Set engine to approximate TDC by rotating in normal operating direction until camshaft lobes at cylinder no. 1 are facing each other . See Fig. 20 . 14 . Set engine to TDC by aligning "0/T' mark (0°TDC) on front vibration damper with cast boss on lower timing chain cover. See Fig. 21 . 15 . Remove vibration damper mounting bolts and remove vibration damper and pulley. See Fig. 22 . CAMSHAFT TIMING CHAINS, 6-CYLINDER

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Fig . 18 . Oil baffle' cover being removed .

Fig . 20. Engine set to approximate TDC . Camshaft lobes face in and arrows on sprockets point up (arrows) .

B1 1123a

Fig . 21 . O/T (0°TDC) mark on vibration damper aligned with boss on timing chain cover (arrow) . Fig . 19. Upper timing chain cover mounting nuts (arrows) on preVANOS engines . 16 . Secure crankshaft hub to prevent crankshaft from turning . Using a socket, loosen but do not remove crankshaft hub center bolt. NOTEThe crankshaft hub center bolt is tightened to a torque of 410 Nm (300 ft-ib). A heavy duty holding device, such as BMW special tool no. 112150, should be used to hold the crankshaft hub stationary while the bolt is loosened. Use a heavy duty 314-inch drive socket and breaker bar to break the bolt free. CAMSHAFT TIMING CHAINS, 6-CYLINDER

17 . Lock crankshaft in TDC position by inserting BMW special tool no. 11 2 300 through transmission bellhousing and into hole in flywheel or drive plate . See Fig . 23 . NOTEConfirm that the locking tool has been correctly installed by trying to rotate the crankshaft. 18 . Remove crankshaft hub bolt and washer. Remove hub from crankshaft . 19 . Remove cylinder head cover mounting studs at rear of head . Lock camshafts at TDC using BMW special tool no. 11 3 240 at ends of camshafts . See Fig . 24. .

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Fig . 24. BMW special tool no . 113 240 installed on rear of camshafts to position camshafts at TDC . (M44 camshafts shown . Other engines are similar.)

Fig . 22. Vibration damper with drive belt pulley being removed . Note hub locating dowel (arrow) .

Fig . 25 . Primary chain tensioner plug (arrow) .

Fig . 23 . BMW special tool no . 11 2 300 installed through bellhousing and into flywheel . 20. Remove primary chain tensioner plug and primary chain tensioner . See Fig . 25 .

CAUTION" Check that tool is squarely seated on cytinder head gasket surface . If necessary, rotate camshafts slightly using a 24 mm wrench " On pre-VANOS engines (engines built up to 892), the camshaft locking tool may not fit correctly when the crankshaft is set to TDC. Do not assume the valve train is out of time . On some engines, valve overlap may have been reduced as a dealer service campaign to correct for an uneven idle . Check the timing by placing a 3mm drill bit under the left and right outside edges while pressíng down on the center of the tool (tool center bolts loosened). If the tool now fits, the campaign has been done on the engine.

CAMSHAFT TIMING CHAINS, 6-CYLINDER

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21 . On 1993 and lates engines: Remove access plugs from VANOS control unit in front of exhaust camshaft sprocket . Remove 4 bolts from exhaust camshaft sprocket (use Tono El 0 socket). See Fig. 26 .

24 . On 1993 and later engines:

" Remove VANOS control unit as described later in this repair group. " Remove intake camshaft sprocket mounting nuts . " Remove intake and exhaust sprockets together with secondary chain. Note location of thrust washers and spring plate (where applicable) on intake sprocket . NOTEHold the camshaft stationary (at hex on camshaft) when loosening or tightening sprocket mounting boits. CAUTIONThe crankshaft must not be allowed to rotate once the timing chain is removed. The pistons can contact the valves.

25 . On 1992 engines: 0013056

Fig. 26 . Exhaust camshaft mounting bolts (arrows) . 22 . Depress secondary timing chain tensiones and lock down by inserting stiff wire into the openings in rear of tensioner. See Fig. 27 .

" Remove from intake and exhaust sprocket mounting bolts. " Remove sprockets together with secondary chain.

26 . Remove bolts holding lower timing chain cover to cylinder head (use Torx E8 socket). See Fig. 28 .

M R111 :R Fig. 28 . Cylinder head-to-timing chain cover mounting bolts (arrows) . Fig. 27 . Secondary timing chain tensioner being locked down on M50 engine . Press tensioner down and insert locking wire through holes (arrows) . Tensioner on M52/S52 US engines vary slight23 . Remove secondary chain tensioner and lift out primary chain guide.

27 . Using a drift, drive two locatiog dowels in left and right sides of lower timing chain cover toward rear of car. Remove cover mounting boits and carefully lift cover off. See Fig. 29 . CA UTIONUse care when removing the cover from the cylinder head gasket. If the cover is stuck, use a sharp knife to separate it from the head gasket.

CAMSHAFT TIMING CHAINS, 6-CYLINDER

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

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29 . Lift primary chain sprocket off exhaust camshaft and remove chain . NOTE" If any of the sprockets are being replaced due to wear, the chain should also be replaced. " If the crankshaft sprocket requires replacement, the oil pump drive sprocket and chain must be removed as described under 119 Lubrication System .

Camshaft timing chains, installing (6-cylinder engines)

Inspect timing chain sprockets . Sprockets that have worn or missing teeth should be replaced . Inspect guide rail and tensioner rail for deep grooves caused by chain contact . Replace any parí that is worn . B11126

Fig . 29 . Lower timing chain cover mounting bolts (arrows) and dowel locations (A) . Coolant hose fitting B is replaced by coolant pipe pressure fitting in later models . NOTE" The timing chain cover can be removed with the coolant pump installed. " Use care when removing the chain cover from the coolant pipe or hose at the rear of the cover. 28. Remove remaining Torx bolt from timing chain guide. See Fig . 30 .

The procedure outlined below assumes that the camshafts and the crankshaft are locked in the TDC installation position with special tools (shown earlier in Fig . 23 and Fig . 24) . NOTEOn pre-VANOS engines (engines built up to 8-92), the camshaft locking tool (Fig. 24) should be raised up on either side by 3mm (use feeler gauge or dril¡ bits). Be sure the clamping bolts on tool are loose and the center of the tool is contacting the cylinder head surface . This service campaign helps improve idle characteristics by reducing valve overlap. 1 . Install primary timing chain to crankshaft sprocket and tie it up through cylinder head opening . 2 . Using new gaskets and coolant pipe O-ring ; insta¡¡ lower timing chain cover : " Drive timing cover doweis in until they just protrude slightly from sealing surface . " Apply a small bead of silicon sealer (3-Bond 1209© or equivalent) to corners of cylinder head where timing cover meets cylinder head and engine block . " Tap cover into position to engage doweis . " Install mounting bolts hand tight, including two outer Torx bolts from above . " Drive doweis in flush to front of cover. " Tighten cover mounting bolts alternately and in stages .

Tightening Torque

" Lower timing cover to cylinder block M7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 ft-Ib) M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (15 ft-Ib)

Fig . 30 . Timing chain guide mounting bolt (A) .

3 . Insta¡¡ oil pan using a new gasket . See 119 Lubrication Systern .

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4. Mount primary timing chain sprocket to primary chain so that arrow on sprocket faces up . Mount sprocket to camshaft so that tapped holes in camshaft are on left side of elongated holes in sprocket. See Fig. 31 .

B11136

Fig. 32 . Secondary chain sprockets being installed. Attach sprockets with arrows pointing up and elongated holes centered to threaded holes in shaft flange .

Fig. 31 . Primary timing chain sprocket correctly aligned to exhaust camshaft . Elongated sprocket holes should be aligned to left side of threaded camshaft holes.

NOTEOn engines built beginning from March 1995, the VANOS intake cam sprocket assembly was updated to ínclude a spring plate and two thrust washers. See Fig. 33 .

5. On 1993 and later engines:Install BMW special tool no . 11-3 390 into primary timíng chain tensioner sleeve . Thread tool in finger tight until slack is removed from chain. " Check that elongated holes in primary sprocket are centered to bolt holes in camshaft and chain is free of slack. NOTEBMW special tool no. 11 3 390 ís a dummy primary chaín tensioner and simulates the function of the hydraulic tensíoner.

6. Install primary timing chain guide and secondary chain tensioner. Tighten mounting bolts. (Tensioner remains locked down for now.)

Fig. 33 . VANOS spring plate and thrust washers on engines built 3/95 and later.

7. Install cylinder identification trigger píate to front of intake camshaft. On 1993 and later engines, instan thrust washer to front of intake camshaft .

10 . On 1993 and later cars, tighten nuts at intake camshaft sprocket .

8. Insta¡¡ secondary chain sprockets and chain as an assembly so that arrows on sprockets are pointing up . Center mounting holes in sprockets to bolt holes in camshafts. See Fig. 32 .

Tightening Torque (1996 and later) " Intake camshaft sprocket nut to stud (M6) . . . . . . . . . . . . . .10 t 1 Nm (89 ± 9 in-lb)

9. On 1993 and later engines: Insta¡¡ thrust washers and spring plate (where applicable) to intake cam sprocket .

CAMSHAFT TIMING CHAINS, 6-CYLINDER

11 . On 1992 engines: Insta¡¡ primary chain tensioner so that cutout in tensioner piston engages chain rail . See Fig. 34 . Check that chain is free of slack.

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18 . Insta¡¡ crankshaft hub and washer while aligning woodruff key. Hold hub stationary and tighten mounting bolt. Install vibration damper and pulley, making sure that locating pin in hub engages hole in vibration damper. NOTEWhen installing crankshaft hub mounting bolt, the stepped (shouldered) side of the washer should fase the hub.

Tightening Torques Crankshaft hub to crankshaft (stretch boltalways replace) . . . . . . . . 410 ± 20 Nm (300 ± 15 ft-1b) " Vibration damper and pulley to crankshaft hub (M8) . . . . . . . . . . . . 22 Nm (17 ft-Ib) Fig . 34 . Primary timíng chain tensioner being instafed . Piston cutout must be in position shown to engage chain rail . 12 . On 1993 and later engines : Install VANOS control unit as described later in this repair group. 13 . Unlock and release secondary chaintensioner. 14 . On 1992 engines : Tighten intake and exhaust timing chain sprocket bolts alternately in two stages, working at intake side first . Tightening Torques " Secondary timing chaira sprockets to camshafts (M7 Torx bolts) Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (44 in-lb) Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (17 ft-Ib)

19 . Turn engine over by hand in direction of rotation atleast two full rotations . Reinstall camshaft and crankshaft locking tools to check engine timing . Remove locking tools if no faults are found . NOTEOn pre-VANOS engines, be sure to install the 3mm drill bits on left and right sides of tool. 20 . On 1993 and later engines : Remove BMW special tool 11 3 390 (dummy tensioner) . Install primary chain tensioner so that cutout in tensioner piston engages the chain rail . See Fig . 34 . Install and tighten access plugs in VANOS control unit .

Tightening Torques

15 . On 1992 engines: Install upper timing chain cover to cylinder head using a new gasket. Apply a small amount of liquid gasket sealer (3-Bond 1209® or equivalent) around cover alignment dowels .

" Access plugs to VANOS control unit . . . . . . . . . . . . . 50 Nm (37 ft-Ib) " Primary timing chain tensioner to tensioner sleeve M50/S50US engine . . . . . . . . . . . . . . 50 Nm (37 ft-Ib) M52/S52US engine . . . . . . . . . . . . . . 40 Nm (30 ft-Ib)

16 . On 1993 and later engines : Preload primary chain by tightening BMW special tool no. 11 3 390 (dummy chain tensioner) to 1 .3 Nm (11 in-lb) . Then tighten exhaust camshaft sprocket bolts alternately in two stages.

21 . Install cylinder head cover mounting studs . Insta¡¡ oil baffle cover. Install cylinder head cover.

Tightening Torques (1993 and later engines)

Tightening Torque " Cylinder head cover to cylinder head . . . . . . . . . . . . . . . . .10 Nm (89 in-lb)

" Exhaust camshaft sprockets to camshafts (M7 Torx bolts) Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (44 in-lb) Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (17 ft-Ib) 17 . Remove flywheel locking tool from transmission bellhousing . Remove camshaft locking tool from rear of cylinder head .

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22 . Installation of remaining parts is reverse of removal, noting the following: " When installing thermostat, make sure arrow or vent hole faces up, if applicable . " Refill cooling system as described in 170 Radiator and Coming System . " Install oil pan as described in 119 Lubrication System. " Fill engine with oil and install a new oil filter as described in 020 Maintenance Program . " Insta¡¡ ground wires at cylinder head cover mounting studs and at front of cylinder head and thermostat housing, where applicable . Tightening Torques " Coolant drain plug to cylinder block . . 25 Nm (18 ft-Ib) " Radiator cooling fan to coolant pump . 40 Nm (30 ft-Ib) " Radiator drain screw to radiator . . . . 2.5 Nm (22 in-Ib) " Upper timing chain cover to cylinder head M6 nut . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) M8 bolt . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (17 ft-Ib) " VANOS control unit to cylinder head M6 nut . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) M8 bolt . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (17 ft-Ib) " VANOS oil supply pipe to VANOS control unit banjo bolt . . . . . . . . . . . . . . . . . . . . . . 32 Nm (24 ft-Ib)

VANOS (VARIABLE VALVE TIMING) 1993 and later 6-cylinder engines are equipped with a variable valve timing system called VANOS. This system is controlled by the engine management system and dynamically adjusts intake camshaft timing based on engine load, engine speed and engine temperature . The main components of the VANOS system are thecontrol unit with piston housing and integral spool valve, and the modified intake camshaft. See Fig. 35 .

When the engine is running, the piston housing is supplied with pressurized engine oil. At idie, the solenoid is in the off position (de-energized) and valve timing is maintained in the normal position : When the solenoid is energized, the gear cup piston movesforward to advance the camshaft by a maximum of 12 .5 . WARNING Special BMW service tools are required to check and repair the VANOS System. Read the procedures through before beginning the job.

VANOS system operation, testing There are 3 special tools required to check VANOS operation ; an electrical test lead (BMW special tool no. 12 6 410), an air line fitting (BMW special tool no . 11 3 450), and a crankshaft TDC locking tool (BMW special tool no . 112 300) . The test leal is used to power the solenoid, simulating the ground signal from the DME control unit . The air line fitting takes the place of the oil supply line fitting to simulate oil Aressure . The locking tool positions and locks the crankshaft at TDC, cylinder no . l . 1 . Remove alternator cooling air duct. 2. Disconnect crankcase ventilation hose fitting from cylinder head cover. 3. Remove top plastic engine covers . Disconnect ignition coil harness connectors from cofs . Remove ignition coils. 4. Remove cylinder head cover mounting bolts and remove cylinder head cover. Unclip and remove oil baffle cover from above intake camshaft . See 113 Cylinder Head Removal and installation . NOTENote the arrangement of the cylinder head cover bolt insulators and gaskets during removal.

5. Set engine to approximate TDC by rotating in normal operating direction until camshaft lobes at cylinder no . 1 are facing each other. See Fig. 20 . 6. Set engine to TDC by aligning "0/T" mark (0°TDC) on front vibration damper with cast boss on lower timing chain cover. See Fig . 21 . 7. Lock crankshaft in position by inserting BMW special tool no. 11 2 300 through transmission bellhousing and into hole in flywheel or drive plate. See Fig. 36 . B11001

Fig. 35 . VANOS control unit with modified intake camshaft . VANOS (VARIABLE VA LVE TIMING)

NOTEConfirm that the locking tool has been correctly installed by trying to rotate the crankshaft.

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11 . Disconnect harness connector from VANOS solenoid . Connect BMW special tool no . 12 6 410 (electrical test lead) to VANOS solenoid connector. " Connect positive (+) test lead to positive (+) terminal of battery Connect negative (-) test lead to chassis ground . solenoid should audibly click and intake camshaft should advance . CA UTION" Be sure to connect the test hamess polarity correctly. lf the polarity is reversed, the intemal diode in the VANOS solenoid will be destroyed. Although the solenoid will still function with a faulty diode, a fault code may be set in the ECM memory. " To confirm voltage polarity, turn the ignition on and check for positive (+) battery voltage at the terminal corresponding to the redlwhite wire in the main harness connector. Check that the positive terminal (+) in the main connector corresponds to the same terminal in the solenoid connector that is being connected to the battery. Fig . 36 . BMW special tool no . 11 2 300 installed through bellhousing and finto flywheel . 8 . Remove oil line fitting from VANOS control unit . NOTEWrap the VANOS oil line fitting with a shop to absorb leaking oil. 9 . Using hollow bolt and seals from oil supply line, instan BMW special tool no . 11 3 450 (air line fitting) and connect a supply of compressed air (30-115 psi) to VANOS oil fitting . 10 . Measure and record distance between trigger plate edge and side of secondary timing chain tensioner. See Fig . 37 .

12 . With solenoid actuated, measure and record new distance between trigger plate edge and side'of secondary timing chain tensioner, as shown in Fig . 37 . 13 . Difference between first measurement (step 10) and second measurement (step 12) should be at least 8 .5 mm (0 .3346 in .) . lf any faults are found, solenoid may be faulty, or hydraulic control unit may be faulty or incorrectly installed . 14 . Check VANOS solenoid by removing it from control unit . Check that solenoid plunger and control unit plunger move freely. Install solenoid using tighteníng torque given below . NOTE" The solenoid is available as a replacement part. lf the control unit plunger is sticking, the complete control unit will ha ve to be replaced. " lf the VANOS system does not advance correctly and no other faults can be found, it is possible that the VANOS control unit may Nave been fnstalled incorrectly-especially if the camshaft sprockets have prevíously been removed for other repairs. Check the installation by removing and reinstalling the control unit as described later.

Fig. 37 . VANOS reference measurement (dimension A) between trigger píate (sender gear) and side of secondary chain tensioner. VANOS (VARIABLE VALVE TIMING)

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CAMSHAFT TIMING CHAIN

15 . Remove crankshaft locking tool . Remove special test equipment. Insta¡¡ oil supply line using new seals and reconnect solenoid connector. Remainder of installation is reverse of removal. Tightening Torque " Cylinder head cover to cylinder head . 10 Nm (89 in-lb) " VANOS oil supply line to VANOS control unit (banjo bolt) . . . . . . . . . . . 32 Nm (24 ft-Ib) " VANOS solenoid lo VANOS control unit . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft-Ib)

VANOS control unit, removing Special BMW service tools are required lo remove and install the VANOS control unit . Read the procedure through before starting the job. 1 . Remove radiator cooling fan shroud and cooling fan. See 170 Radiator and Cooling System . CAUTIONRadiator fan has left hand threads.

2. Remove top plastic engine covers . Disconnect ignition coil harness connectors from coils. Remove ignition coils. Remove cylinder head cover. Unclip and remove oil baffle cover from above intake camshaft .See 113 Cylinder Head Removal and Installation . NOTEMake note of the mounting bolt insulator arrangement during removal of the cylinder head cover.

3. Set engine lo TDC by rotating engine in normal operating direction until camshaft lobes at cylinder no. 1 are facing each other and "0/T" mark (0°TDC) on vibration damper lines up with cast boss on lower timing chain cover. See Fig. 38 . 4. Lock crankshaft at TDC by inserting BMW special tool no. 11 2 300 through transmission bellhousing and finto flywheel or drive plate. Refer to Fig . 36 given earlier. NOTEConfirm that the locking tool has been correctly installed by trying to rotate the crankshaft.

5. Remove three cylinder head cover mounting studs from rear of head . Lock camshafts at TDC by mounting BMW special tool no . 11 3 240 at ends of camshafts. Check that tool is squarely seated on cylinder head gasket surface. If necessary, rotate camshafts slightly using a 24 mm wrench . Refer to Fig. 24 given earlier.

VANOS (VARIABLE VALVE TIMING)

Fig. 38. Camshafts positioned at TDC-Cyl . No . 1 cam lobes face in Note 0/T mark (0°TDC) on vibration damper alígned with boss on front cover. CA UTIONThe camshafts must be locked in the TDC position using the special service tool or an equivalent before removing the timing chain . The arrows on the sprockets should not be used to accurately set the engine to TDC The special tool holds the camshafts parallel to each other and perpendicular to the valve cover gasket surface .

6. Disconnect harness connector and oil line fitting from bottom of VANOS control unit . NOTEWrap the VANOS oil fine fitting with a shop rag to absorb leaking oil.

7. Remove two access plugs from VANOS control unit in front of exhaust camshaft sprocket. Loosen 4 exhaust camshaft sprocket mounting bolts but do not remove (Torx El 0 socket). NOTERemoval of the access plugs allows the lower exhaust camshaft sprocket mounting bolts to be accessed.

8. Depress secondary timing chain tensioner and lock it in down position by inserting a stiff wire into rear of tensioner. See Fig. 27 . 9. Remove VANOS control unít mounting nuts and bolt at front of cylinder head .

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10 . On cars built up to 3/95 : Slide control unit off front of cylinder head, hand turning the exhaust sprocket clockwise (as viewed from front) as the unit is removed. 11 . On cars built 3/95 and latee: Use a spanner tool to rotate exhaust sprocket until stop on' intake sprocket is contacted. See Fig. 39 . Then slide control unit off front of cylinder head .

EMAÑ Fig. 40. Primary timing chain tensioner (arrow). Remove tensioner slowly to relieve spring tension beneath end plug .

0012514

Fig. 39 . On VANOS control unit with spring plate (cars built 3/95 and later), rotate exhaust camshaft sprocket clockwise until intake camshaft contacts stop . BMW special tool 11 5 490 shown.

VANOS control unit, installing CAUTION Incorrect installation of the VANOS control may result in damage to the engine valvetráin .

1 . Lock camshafts and crankshaft in TDC position with BMW special tools as described above in removal procedure . CA UTIONThe camshafts and crankshaft must be locked in the TDC position using BMW special tools no. 11 2 300 and 113 240 . If the camshafts and crankshaft are not at TDC, the valves can contact the pistons when the engine is turned over. NOTEBe sure the secondary timing chain tensioner is locked down and the exhaust camshaft mounting bolts are loose before proceeding.

3. Install BMW special tool no . 11 3 390 into primary timing chain tensioner sleeve . Thread tool in finger tight to remove chain slack. NOTEBMW special tool no. 113 '390 is a dummy chain tensioner and simulates the function of the tensioner.

4. Hand turn secondary sprockets clockwise (as viewed from front of engine) until sprockets contact stops. 5. Apply a small amount of ¡¡quid gasket sealer (3-Bond 1209® or equivalent) to VANOS housing alignment doweis on front of cylinder head . lnstall a new gasket . 6. Push VANOS piston gear cup finto VANOS housing until it bottoms out in housing. Position VANOS control unit into place, but do not engage splines on gear cup. 7. On cars built up to 3/95 : " Hand turn exhaust sprocket counterclockwise (as viewed from front of engine) only enough to mesh gear cup splines with camshaft gear : " Slowly push VANOS control unit in until fully seated, guiding chains in counterclockwise direction .

2. Remove primary timing chain tensioner from side of cylinder head . See Fig. 40 .

VANOS (VARIABLE VALVE TIMING)

117- 1 8

CAMSHAFT TIMING CHAIN

CAUTIONIt is crítical that the exhaust camshaft sprocket be turned only the mínimum amount necessary to engage the gear cup. If this procedure is done íncorrectly, the VANOS system may not function throughout íts full range. NOTEAs the control unit is installed, the secondary sprockets will rotate in the counterclockwise direction. It may be necessary to guide sprockets counterclockwise as the control unit is installed.

8. On cars built from 3/95 : Use a spanner tool (See Fig. 39 .), turn exhaust sprocket counterclockwise (as víewed from front of engine) only enough to mesh gear cup splines with camshaft gear. Slowly push VANOS control unit towards camshaft until it is fully seated, guiding chains in counterclockwise direction. CA UTIONEnsure that the first available tooth engages.

9. Install and tighten control unit nuts and bolt . 10. Connect harness connector to VANOS solenoid . Using new seals, insta¡¡ oil line fitting. Tightening Torques " VANOS control unit to cylinder head M6 nut . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) M8 bolt . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (17 ft-Ib) " VANOS oil supply line to control unit . 32 Nm (24 ft-Ib) 11 . Slowly unlock and release secondary chain tensioner. 12 . Preload primary chain by tightening BMW special tool no . 112 240 (dummy chain tensioner) to 1 .3 Nm (11 inlb). Then tighten exhaust camshaft sprocket mounting bolts alternately in two stages .

13 . Remove flywheel locking tool from transmission bellhousing. Remove camshaft locking tool from rear of cylinder head . 14 . Turn engine over by hand at least two fui¡ crankshaft rotations. Reinstall camshaft locking tool and flywheel locking tool to make sure all adjustments are correct. If settings are correct, remove locking tools. 15 . Remove BMW special tool 112 420 (dummy chain tensioner) from side of cylinder head . Install primary chain tensioner so that cutout in tensioner piston engages chain rail . See Fig. 34 . Using new seals, install and tighten access plugs in VANOS control unit . Tightening Torque " Access plugs to VANOS control unit . . . . . . . . . . . . . . . 50 Nm (37 ft-lb) " Primary timing chain tensioner plug to tensioner sleeve M50/S50USengine . . . . . . . . . . . . . . . 50 Nm (37 ft-Ib) M52/S52US engine . . . . . . . . . . . . . . 40 Nm (30 ft-Ib) 16 . Install oil baffle cover above intake camshaft . Install three cylinder head cover mounting studs to rear of head . Instali cylinder head cover. Tightening Torque " Cylinder head cover to cylinder head (M6 screws) . . . . . . 10 Nm (89 in-Ib) 17 . Installation of remaining parts is reverse of removal . NOTEBe sure to install the ground wíres at the cylinder head cover mounting studs and at the front of the cylinder head, if applicable .

Tightening Torque " Secondarytiming chain sprockets to camshafts (Tora boits) Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . 5 Nm (44 in-lb) Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (17 ft-Ib)

VANOS (VARIABLE VALVE TIMING)

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

LUBRICATION SYSTEM

119-1

119 Lubrication System GENERAL . . . . . . . . . . . . . . . . . . . , , . . . . . . . 119-1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 119-1

Oil pressure, checking . . . . . . . . . . . . . . . . . . 119-1 Oil pressure warning system, testing . . . . . . . 119-2

OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119-2 Oil pan, removing and installing (4-cylinder engines) . . . . . . . . . . . . . . . . . . . 119-2

OH pan, removing and installing (6-cylinder engine, 1992 models) . . . . . . . . . 119-4 Oil pan, removing and installing (6-cylinder engine, 1993 and later models) .119-6

OIL PUMP . . . . . . . . . . . . . . . . . . . . . .

.119-8 Oil pump, removing and installing (4-cylinder engine) . . . . . . . . . . . . . . . . . . . .119-8 Oil pump, removing and installing (6-cylinder engine) . . . . . . . . . . . . . . . . . . .119-10

GENERAL

Oil pressure, checking

The oil pan and the oil pump can be removed with the engine installed, although engine liftinglsupport equipment is necessary.

To perform an oíl pressure test, BMW specifies special tools that attach to the top of the oíl filter housing. The following procedure works well using standard automotive oil pressure testing equipment attached to the oil pressure switch port in the engine . In some engines, however, access to this port may be extremely restricted .

NOTE-

Oil change procedure and oil filter replacement are covered in 020 Maintenance Program.

Al¡ engines are equipped with an oil pressure warning system to help prevent engine damage . Other safety features include: " A filter bypass to provide lubrication should the oil filter become clogged. " An oil pump pressure relief valve to prevent excessive system pressure .

1 . Disconnect harness connector from oil pressure switch and remove switch . See Fig. 1 . NOTE-

Thoroughly clean around the oil pressure switch before removing it.

TROUBLESHOOTING The lubrication warning system consists of an oil pressure switch mounted in the oil circuit and an instrument panel warning light. CAUTION-

If the red oil pressure warning light comes on or flashes on while driving, always assume that the oil pressure is low.

Fig. 1. Oil pressure switch location on M50 engine (arrow).

TROUBLESHOOTING

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

119-2

LUBRICATION SYSTEM

Component Location " Oil pressure switch all engines . . . . . . . . . . . . . . . . . . . ora oil filter housing CAUTION-

Some oil may drain out as the oil pressure switch is removed. Use a rag to soak up any spills.

2. Install pressure gauge in place of switch . 3. With gauge instalied, start engine and allow to reach operating temperature . Check oil pressure both cold and hot. NOTE-

For the most accurate test results, the engine oil (and filter) should be new and of the correct grade.

Oil Pressure " ¡dle (mínimum) . . . . . . . . . . . . . . . . . . . . 0.5 bar (7 psi) " Regulated pressure (elevated engine speed) 4-cylinder engines . . . . . . . . 4.3 ± 0.2 bar (63 t 3 psi) 6-cylinder engines . . . . . . . . . . . . . . . . 4.0 bar (59 psi) 4. Remove pressure gauge and reinstall pressure switch . If testing shows low oil pressure, one or more of the following conditions may be indicated: " Worn or faulty oii pump . " Worn or faulty engine bearings Severe engine wear. Al¡ of these conditions indicate the need for major repairs.

Oil pressure warning system, testing When the ignition is tumed ora, the oil pressure warning light comes ora. When the engine ís started and the oil pressure rises slightly, the oil pressure switch opens and the warning light goes out. Make sure the oil leve¡ is correct before making tests. 1 . Turra ignition switch ora.

" Warning light ora instrument panel must light up.

2. Remove connector from oil pressure switch .

" Warning light ora instrument panel must go out.

OIL PAN

NOTE-

If the light does not go out, the wiring to the switch is most likely grounded somewhere between the switch terminal and the warning light. Sea Electrical Wiring Diagrams at rear of manual for electrical schematics.

3. If warning light does not light when ignition is ora, remove connector from oil pressure switch and use a jumper wire to ground connector terminal to a clean metal surface. NOTE -

If the warning light comes ora, check the switch as descríbed in the next step. If the warning light does not come ora, the wiring to the instrument cluster or to the light itself is faulty.

4. To test switch, connect ara ohmmeter between terminal in switch body and ground . With engine off, these should be continuity. With engine running, oil pressure should opera switch and there should be no continuity Replace a faulty switch . WARNING Keep in mind that low oil pressure may be preventing the switch from tuming the light out. If the light remains ora while the engine is running, check the oil pressure as described earlier. Do not drive the car until the problem is corrected. The engine may be severely damaged.

OIL PAN The oil pan can be removed with the engine instalied, although specíal engine support equipment will be needed .

Oil pan, removing and installing (4-cylinder engines) 1 . Raise car arad place securely ora jackstands . 2 . Remove splash shíeld(s) from under engine, where applicable . 3. Drain engine oil as described in 020 Maintenance Program . 4. Disconnect vacuum hose adapter from vacuum brake booster at rear of engine compartment. 5. Remove oil dipstick guide tube mounting nut and pull guide tube from oil pan. See Fig. 2.

LUBRICATION SYSTEM

119-3

NOTE -

The guide tube is sealed in the pan with an O-ring . Check that the O-ring comes out with the tube . Use a new O-ring when installing the tube.

0011960

Fig. 3. Stabilizer bar link nut (A) and control arm bushing carrier bolts (B) . Right side shows. 10 . Remove bolts from left and right sides of suspension crossmember. Remove M10 nuts from bottom of left and right engine mounts . Lower crossmember as far as possible . See Fig . 4 . Fig . 2 .

Oil dipstick guide tube mounting nut (arrow) on M44 engine . Use new O-ring at base of tube during installatidn .

6 . Install engine lifting equipment at front engine lifting point and raise engine approximately 5 mm (1/4 inch) until engine weight is supported . 7 . Working beneath car, separate steering column shaft from steering rack at universal joint . " Point wheels straight ahead before disconnecting shaft from rack . Mark steering column shaft joint to steering rack spíndle . See 320 Steering and Wheel Alignment .

CAUTION-

In order to avoíd the need for front-end realignment, do not unbolt power steering rack from suspension crossmember.

8 . Support suspension crossmember (subframe) from below using appropriate jacking equipment. 9 . At left and right sides, unbolt control arm bushing carriers from body. Disconnect stabilizer bar links from control arms . See Fig . 3 .

uu1ibb4

Fig . 4. Suspension crossmember bolts (A) and lower engine mounting nut (B). Right side shows . 11 . Remove clamping brackets holding fuel lines to oil pan . 12 . On cars with automatic transmission, remove ATF cooler line brackets from oil pan. 13 . Remove engine drive belt from power steering pump . See 020 Maintenance Program . 14 . Unbolt power steering pump bracket and remove bracket with pump. Hang pump from chassis using wire .

OIL PAN

119-4

LUBRICATION SYSTEM

15 . Remove oil pan screws. Lower and remove oil pan toward rear. CAUTION' lf the oil pan does not separate easily from the en-

gine cylinder block, make sure all mounting bolis have been removed. If necessary, a few taps with a rubber mallet should break it free . Never pry the oil pan loose.

16 . Installation is reverse of removal . " Thoroughly clean all old gasket material from mating surfaces and use a new gasket. " Apply a small amount of non-hardening sealer (3Bond Ol209 or equivalent) to oil pan gasket directly below joints for end cover and front timing case cover. See Fig. 5 . " When installing oil pan to engine, tighten forward screws first, then tighten rear. " Fill engine with oil as described in 020 Maintenance Program .

Tightening Torques " Control arm bushing carrier to body (M10 bolt) . . . . . . . . . . . . . . . 42 Nm (31 ft-Ib) " Engine mount to suspension crossmember (M10 nut) . 42 Nm (31 ft-Ib) " Front suspension crossmember to body . . . . . . . . . . . . . . See 310 Front SusPension " Oil pan to engine block (M6 bolt) 8.8 grade . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) 10 .9 grade . . . . . . . . . . . . . . . . . . . . . . 12 Nm (9 ft-Ib) " Power steering pump to bracket (self-locking nuts) . . . . . . . . . . . . . . . . 22 Nm (16 ft-Ib) " Power steering pump bracket to engine block or oil pan (self-locking nuts) . . . 22 Nm (16 ft-Ib) " Stabilizer bar link to control arm M8 nut . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (17 ft-Ib) M10 nut . . . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 Ib-ft) " Steering column universal joint to steering rack spindle (M8 bolt) . . . . 19 Nm (14 ft-ib)

Oil pan, removing and installing (6-cylinder engine, 1992 models) NOTE-

Cars built up to 9/92 (1992 models) use a different suspension crossmember than later production cars. Oil pan removal procedure on the earlier cars requires that the engine be raised and supported from above.

1 . Raise car and place securely on jackstands . 2. Remove splash shield(s) from under engine, where applicable . 0011950

Fig. 5. Joint-mating areas at oil pan gasket where sealer should be applied (arrows) . Apply a bead 3 mm wide by 2 mm high . WARNING -

3. Drain engine oil as described in 020 Maintenance Program . 4. Remove complete exhaust system . See 180 Exhaust System .

Always use new bolis when mounting the subframe to the body. The one-time only bolis should be replaced any time they are removed.

5. Remove air filter housing complete with mass air flow sensor. See 113 Cylinder Head Removal and Installation .

NOTE-

6. Remove alternator cooling duct from alternator and radiator support.

The oil pickup is attached to the oil pan using self-tapping screws. For this reason no threading for the pickup is present on new oil pans. Replace the seal for the pickup and use the oíd screws to rea ttach the pickup to the pan .

Center the steering spindle to the steering rack before installing the steering column shaft. See 320 Steering and Wheel Alignment for specific installation markings and procedures. OIL PAN

7. Remove radiator cooling fan and fan shroud . Remove radiator securing clips at top of radiator . See 170 Radiator and Cooling System . NOTE-

The radiator cooling fan nut (32 mm wrench) has left hand threads.

LUBRICATION SYSTEM

119-5

8. Remove air plenum from rear of engine compartment. See 640 Heating and Air Conditioning . 9. Release drive belt tension and remove alternator drive belt . Remove A/C compressor drive belt . See Fig. 6.

Fig. 7. Power steering pump mounting bolts (arrows) .

B11143

Fig. 6. To remove poly-ribbed drive belt, pry cover from front of tensioner. Then using 8 mm hex key, turn tensioner clockwise (arrow) to release tension and slip belt off pulleys. 10 . Unbolt power steering reservoir and pull reservoir off engine mount bracket. 11 . Without disconnecting fluid lines, remove power steering bracket (with pump) from oil pan and engine block. See Fig. 7. Disconnect fluid lines from bracket on engine mount. Hang pump from chassis using wire . 12. Without disconnecting refrigerant lines, remove A/C compressor from engine block. Hang compressor from chassis using wire . See 640 Heating and Air Conditioning. 13. Remove oil dipstick guide tube mounting bolt and remove tube . See Fig . 8. NOTEThe guide tube is sealed in the oil pan with an O-ring. Check that the O-ring comes out with the tube. Use a new O-ring when installing the tube.

14. On cars with automatic transmission, remove brackets holding ATF cooler lines to oil pan and cylinder block.

Fig. 8. Oil dipstick guide tube being removed . Use a new O-ring (arrow) during installation . 15 . Insta¡¡ engine lifting equipment at front engine lifting point and raise engine just until its weight is supported. 16 . Remove nuts at bottom of left and right engine mounts . Remove ground wire from right engine mount. 1-oosen nuts at top of left and right engine mounts (do not remove).

OIL PAN

119-6

LUBRICATION SYSTEM

17 . Raise engine as much as possible . Check carefully for obstructions, wiring harness clearance and pinched hoses or lines as engine is raised . 18 . Remove oil pan mounting bolts and lower oil pan to subframe crossmember.

NOTE-

If the oil pan does not separate easily from the engine cylinder block, a few taps with a rubber mallet should break it free. Do not pry the oil pan loose.

19 . Remove oil pump sprocket mounting nut. See Fig . 9. Lift sprocket off together with drive chain .

22 . Installation is reverse of removal. " When installing oil pan, apply a b dof non-hardening sealing compound (3-Bond 12090 or equivalent) to front and rear end cover seam areas on block. " Position oil pump pickup tube and oil pan onto block and install pickup tube using a new gasket. " Be sure tab on gasket faces down towards intake of pickup tube . " Tighten forward oil pan screws first, then tighten rear. " Fill engine with oil as described in 020 Maintenance Program. " After adding engine oil, start and run engine . Raise engine speed to 2,500 rpm until oil pressure warning lamp goes out (about 5 seconds) . Tightening Torques " Engine mount to suspension crossmember(M10 nut) . . 42 Nm (31 ft-Ib) " Oil pan to engine block (M6 bolt) 8.8 grade . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) 10 .9 grade . . . . . . . . . . . . . . . . . . . . 12 Nm (106 in-lb) " Oil pump to engine block . . . . . . . . . . 22 Nm (16 ft-Ib) " Oil pump sprocket to oil pump shaft (M1 0x1 left-hand thread) . . . . . . . . . . 25 Nm (18 ft-Ib) " Power steering pump to bracket (self-locking nuts) . . . . . . . . . . . . . . . . 22 Nm (16 ft-lb) " Power steering pump bracket to engine block or oil pan (self-locking nuts) . . . 22 Nm (16 ft-Ib)

Fig. 9. Oil pump sprocket mounting nut (left-hand thread) on 6-cylinderengine(arrow) .

NOTE-

The oíl pump sprocket nut has left hand threads.

20 . Unbolt oil pump pickup tube from oil pump. Unbolt oil pump from engine block. See Oil pump, removing and installing (6-cylinder engine). 21 . Remove oil pan from rear.

OII pan, removing and installing (6-cylinder engine, 1993 and later modeis) NOTE-

Cars built after 9/92 use a different suspension crossmember ¡han earfier productíon cars. Oil pan removal procedure on the later cars requíres that the engine be supported from aboye and the front suspension crossmember be unbolted and lowered from the chassis .

1 . Raise car and place securely on jackstands . 2. Remove splash shield from under engine, if applicable . 3. Drain engine oil as descríbed in 020 Maintenance Program . 4. Remove alternator cooling duct from alternator and radiator support.

LUBRICATION SYSTEM

119

5. Remove air filter housing complete with mass air flow sensor. See 113 Cylinder Head Removal and Installation . 6. Remove oil dipstick guide tube mounting bolt. Disconnect oil separator hose from base of guide tube and remove tube from oil pan (where applicable) . See Fig. 10 . NOTE-

The guide tube is sealed in the block using an O-ring. Check that the O-ring comes out with the tube. Use a new O-ring when installing the tube .

Fig. 11 . Engine lifting equipment shown installed across engíne . CA UTION-

In order to avoid the need for front-end realignment, do not unbolt power steering rack from suspension crossmember.

11 . Support suspension crossmember from below using appropriate jacking equipment. 12 . Loosen nuts at top of left and right side engine mounts . Remove nuts from bottom of left and right side engine mounts. 13 . At left and right sides, unbolt control arm bushíng carriers from body. Disconnect stabilizer bar links from control arms . Refer to Fig . 3. Fig. 10 . Oil dipstick guide tube being removed. Use new O-ring (arrow) during installation .

14 . Remove bolts from left and right sides of suspension crossmember and lower front axle as far as possible .

7. M50/S50US engine : Using a clean syringe, remove power steering fluid from fluid reservoir. Disconnect power steering fluid lines from steering rack . See 320 Steering and Wheel Alignment.

15 . Remove fuel line clamping brackets from oil pan. On cars with automatic transmission, remove ATF cooler line brackets from oil pan .

8. M52/S52US engine : Unbolt power steering reservoir from engíne, then tie to chassis with wire . 9 . Insta¡¡ engine lifting equipment at front engine lifting point and raise engine approximately 5 mm ('/a inch) until engine weight is supported. See Fig. 11 .

16. Remove oil pan screws . Lower and remove oil pan forward to remove. CA UTION-

If the oil pan does not separate easily from the engine cylinder block, a few taps with a rubber mallet should break it free . Do not pry the oil pan loose.

10 . Working beneath car, separate steering column shaft from steering rack at universal joint. " Mark steering column shaft joint to steering rack spindle . Point wheels straight ahead before disconnecting shaft from rack. See 320 Steering and Wheel Alignment .

OIL PAN

119- 8

LUBRICATION SYSTEM

17 . Installation is reverse of removal . " Thoroughly clean all old gasket material from mating surtaces and use a new gasket . " Apply a small amount of non-hardening sealer (3-Bond 12090 or equivalent) to oil pan gasket directly below joints for and cover and front timing case cover. See Fig. 12 . " Tighten oil pan bolts starting at front first, working toward back (transmission) end. " Fill engine with oil as described in 020 Maintenance Program . " After adding engine oil, start and run engine . Raise engine speed to 2,500 rpm until oíl pressure warning lamp goes out (about 5 seconds) .

Tightening Torques " Control arm bushing carrier to body (M10 bolt) . . . . . . . . . . . . . . . 47 Nm (35 ft-Ib) " Engine mount to suspension crossmember(M10 nut) . . 42 Nm (31 ft-Ib) " Oil pan to engine block (M6 bolt) 8.8 grade . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) 10 .9 grade . . . . . . . . . . . . . . . . . . . . 12 Nm (106 in-lb) " Stabilizer bar link to control arm (M10 nut) . . . . . . . . . . . 42 Nm (31 Ib-ft) " Steering column universal joint to steering rack spindle (M8 bolt) . . . . 19 Nm (14 ft-Ib) " Suspensíon crossmember to body . . . . . . . . . . . . . . See 310 Front Suspension

OIL PUMP Oil pump, removing and installing (4-cylinder engine) Oil pressure on M42 and M44 engines is generated by a gear-type pump mounted to the rear of the front engine cover (timing chain case). The pump is gear-driven off the front of the crankshaft.

NOTEFig. 12 . Joint-mating areas at oil pan gasket where sealer should be applied (arrows) . Apply a bead 3 mm wide by 2 mm high . WARNING " Always use new bolts when mounting the subframe to the body. The one-time only bolts should be replaced any time they are removed. " Special installation instructions apply when installing the front suspension crossmember to the body. See 310 Front Suspension for fastener specifications and tightening torques.

Center the steering spindle to the steering rack before installing the steering column shaft. See 320 Steering and Wheel Alignment for more specific procedures .

Oil pump removal requires lowering of the front suspension and removal of the oil pan, as well as removal of the timing chain assembly.

1 . Disconnect negative (-) battery cable from battery.

CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on paga vÍii.

2. Drain engine oil as described in 020 Maintenance Program . 3. With engine cold, drain coolant. See 170 Radiator and Cooling System . 4. Remove top cover from oil filter housing to allow engine oil to drain into oil pan . Remove oil pan as described earlier. Reinstall oil filter cover. 5. Remove alternator. Unbolt power steering pump from bracket, then remove alternator mountíng bracket. See 121 Battery, Starter, Alternator. 6. Remove crankshaft vibration damper and hub. Then remove upper and lower timing chain covers, complete timing chain, chain sprockets and chain guides . See 117 Camshaft Tíming Chain.

OIL PUMP

LUBRICATION SYSTEM 7. Unbolt timing chain case from front of engine. See Fig. 13 .

119-9

9. Installation is reverse of removal. " Replace al¡ gaskets and O-rings. " Install a new rubber sea¡ (profile gasket) between top of timing chain case and cylinder head . " Be sure to thoroughly clean sealing surfaces . -Use 3-Bond 1209 or equivalent sealant on both sides of sea¡ before installing . 10 . Protect profile gasket using thin sheet metal (BMW special tool no. 11 2 330) when installing timing chain case . See Fig. 15 . " Apply a thin coating of grease to both sides of sheet metal tool and to top surface of profile gasket . " Place sheet metal between gasket and cylinder head and carefully slíde upper chain cover into position . " Tighten al¡ mounting bolts and then carefully withdraw sheet metal. Install timing chain as described in 117 Camshaft Timing Chain.

Fig. 13. Timing chain case mounting bolts (arrows) on M44 engine . 8. Remove cover from oil pump on rear of timing chain case . See Fig. 14 . Inspect oil pump gears and oil pump cavity in timing chain case for wear andlor scoring.

Fig. 15 . Use thin sheet metal (arrow) to protect profile gasket during installation of timing chain case . Carefully withdraw sheet metal after tightening fasteners.

Fig. 14. Oil pump cover mounting bolts (arrows) on M44 engine .

Tightening Torques " Timing chain case to engine block M6 . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Nm (7 .5 ft-Ib) M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft-Ib) " Thermostat housing to upper timing chain cover(M6) . . . . . . . . . . . . 10 Nm (89 in-lb) " OH filter cover to oil filter housing (M8) . . . . . . . . . . . 25 Nm (18 ft-lb) " Oil pump cover to timing chain case (M6) . . . . . . . . . . . . 10 Nm (89 in-lb) " Oil pan to engine block (M6 bolt) 8.8 grade . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) 10 .9 grade . . . . . . . . . . . . . . . . . . . . 12 Nm (106 in-lb) " Alternator to alternator bracket . . . . . 43 Nm (32 ft-Ib)

OIL PUMP

119- 1 0

LUBRICATION SYSTEM

Oil pump, removing and installing (6-cylinder engine) Oil pressure on the 6-cylinder engines is generated by a gear-type pump bolted to the bottom of the engine block. The oil pump is chain driven off the front of the crankshaft. NOTEOil pump removal requires raising the engine (cars built up to 9-92) or lowering the front suspension crossmember (cars built from 9-92) to remove the oil pan .

1 . Drain oil as described in 020 Maintenance Program. 2. Remove oil pan as described earlier.

0011952

3. Remove oil pump sprocket mounting nut (left-hand thread) . See Fig. 16 . Lift sprocket off together with drive chain.

Fig. 17. Oil pump mounting points (1) and pickup tube mountíng points (2). 5. Remove cover from oil pump and check for wear or scoring. Spin oil pump shaft and check that gears turn smoothly. Replace pump if gears spin with difficulty or any wear is present. 6. Installation is reverse of removal, noting the following: " Align sprocket splines to oil pump shaft splines before tightening sprocket nut.

811186

Fig. 16. Oil pump sprocket mounting nut (left-hand thread) on 6-cylinder engine (arrow).

Tightening Torques " Oil pump to engine block (M8) . . . . . . 22 Nm (16 ft-Ib) " Oil pan to engine block (M6 bolt) 8.8 grade . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) 10 .9 grade . . . . . . . . . . . . . . . . . . . . 12 Nm (106 in-lb) " Oil pump sprocket to oil pump shaft (M10x1 left-hand thread) . . . . . . . . . . 25 Nm (18 ft-Ib)

4. Remove mounting bolts from oil pump and oil pump pickup tube . Withdraw pump . NOTENote any spacers between pump and engine block. See Fig. 17. " Note position of locating dowels.

OIL PUMP

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

IGNITION SYSTEM

120-1

120 Ignition System GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120-1

Disabling Ignition System . . . . . . . . . . . . . . . . 120-2 Warnings and Cautions . . . . . . . . . . . . . . . . . . 120-2

IGNITION SYSTEM DIAGNOSTICS . . . . . . 120-3

Basic Troubleshooting Principles . . . . . . . . . . 120-3

IGNITION SYSTEM SERVICE . . . . . . . . . . . 120-3

Checking for Spark . . . . . . . . . . . . . . . . . . . . . 120-3 Ignition coil, testing and replacing (4-cylinder engine) . . . . . . . . . . . . . . . . . . . . 120-3 Ignition coil, testing and replacing (6-cylinder engine) . . . . . . . . . . . . . . . . . . . . 120-4 Crankshaft Positionlrpm Sensor . . . . . . . . . . . 120-5 Crankshaft position/rpm sensor, testing and replacing (front mounted) . . . . . . . . . . . . . . . 120-6 Crankshaft position/rpm sensor, replacing (rear mounted) . . . . . . . . . . . . . . . . . . . . . . . 120-6

GENERAL This repair group covers repair and component replacement information for the ignition system . NOTE" Spark plug replacement is covered in 020 Mainte-

nance Program.

" For fuel related troubleshooting and testing, see 130

Fuel lnjection.

All engines covered by this manual use an advanced engine management system . The engine management system incorporates on-board diagnostics, fuel injection, ignition and other advanced engine control functions.

Table a. Engine Management System Variants Engine code 4-cylinder M42 (1 .8 I) M44 (1 .9 I) 6-cylinder M50 1992 (2 .5 I) 1993-1995 (2 .5 I) M52 1996-1998 (2 .8 I) 1998 (2 .5 I) S50US (3 .0 I) S52US (3 .2 I)

System Bosch DME Ml .7 Bosch DME M5 .2 (OBD II) Bosch DME M8 .1 Bosch DME M33.1 Siemens MS 41 .1 (OBD II) Siemens MS 41 .1 (013D 11) Bosch DME M3 .3 .1 Siemens MS 41 .1 (OBD II)

Camshaft Position (CMP) Sensor . . . . . . . . . . 120-6 Camshaft position (CMP) sensor, replacing (4-cylinder engine) . . . . . . . . . . . . . . . . . . . . 120-6 Camshaft position (CMP) sensor, replacing (6-cylinder engine) . . . . . . . . . . . . . . . . . . . . 120-7 Knock sensors, replacing . . . . . . . . . . . . . . . . . 120-7 Ignition Firing Order . . . . . . . . . . . . . . . . . . . . .120-7 IGNITION SYSTEM SCHEMATICS . . . .

. . .120-7

TABLES

a. Engine Management System Variants . . . . . . 120-1 b. Ignition Coil Resistance (M42 engine) . . . . . . 120-4 c. Ignition Coil Resistance (M44 engine) . . . . . . 120-4 d. Ignition Coil Resistance (6-cylinder engine) . . . . . . . . . . . . . . . . . . . . . 120-5

Troubleshooting and testing of the engine management system should be carried out using the BMW specialized ser vice tester (scan tool). All engines use a distributorless ignition system with indívidual ignition coils for each cylinder. There is no distributor cap or ignition rotor. Each coil can be selectively controlled by the engine control module on a cylinder-by-cylinder basis. On later systems, knock sensors are used to monitor and control ignition knock (ping) and adjust timing accordingly . Ignition timing is electronically controlled and not adjustable. The engine control module (ECM) uses engine load, engine speed, coolant temperature, and intake air temperature as the basic inputs for timing control. Knock detection is also an input to the control module, where applicable . NOTEAll engines covered by this manual, with the exception of the 1992 M50, incorporate knock sensors as part of the engine management system .

The initial ignition point is determined by the crankshaft position/rpm sensor during cranking . Once the engine is running, timing is continually adjusted based on operating conditions . A characteristic ignition map is shown in Fig. 1 . A map similar to the one shown is digitally stored in the engine control module .

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

120-2

Fig . 1 .

IGNITION SYSTEM

Ignition characteristic map . WARNING " Do not touch or disconnect any of the high tension cables at the cotls or spark plugs while the engine ts running or being cranked by the starter. Fatal voltages are present.

WARNING The ignition system is a high-energy system operating in a dangerous voltage range that couldprove to be fatal if exposed terminals or live parts are contacted. Use extreme caution when working on a car with the ignition on or the engine running.

" Before operating the starter without starting the engine (for example when making a compression test) always disable the ignition .

Disabling Ignition System The ignition system operates in a lethal voltage range and should therefore be disabied any time senrice or repair work is being done on the engine that requires the ignition to be switched on . The engine management system can be disabled by removing the main relay . The relay is located in the power distribution box in the left rear of the engine compartment. See Fig . 2 .

CAUTION" Prior to disconnecting the battery, read the battery disconnection cautions gtven at the front of thts manual on page viti. " Do not attempt to disable the ignition by either removing the cotl from the spark plugs (6-cylinder engines) or disconnecting the coll wires from the plugs (4-cylinder engines) . " Connect or disconnect ignition system wires, multiple connectors, and ignition test equipment leads only while the ignition is off. Switch multtmeter functions or measurement ranges onty with the test probes disconnected. " Do not disconnect the battery while the engine ts running. " Many of the tests of ignition system components require the use of high-impedance test equipment to prevent damage to the electrical components. A high impedance digital multimeter should be used for all voltage and resistance tests . An LED test light should be used in place of an incandescent-type test lamp .

0013134

Fig . 2 . Maín system relay (arrow) in power distribution box (left rear of engine compartment) .

GENERAL

" In general, make test connections only as specified by BMW, as described in this manual, or as described by the instrumenta manufacturer.

IGNITION SYSTEM

120-3

IGNITION SYSTEM DIAGNOSTICS

IGNITION SYSTEM SERVICE

Poor driveability may have a variety of causes . The fault may lie with the ignition system, the fuel system, parts of the emission control system, or a combination of the three. Because of these interrelated functions and their effects on each other, it is often difficult to know where to begin looking for problems .

On 4-cylinder engines, an ignition coil pack is mounted to the passenger side strut tower in the engine compartment. The coil pack integrates 4 individual coils.

For this reason, effective troubleshooting should always begin with an interrogation of the On-Board Diagnostic (OBD) system . The OBD system detects certain emissions-related engine management malfunctions . When faults are detected, the OBD system stores a Diagnostic Trouble Code (DTC) in the system ECM. In addition, the Check Engine warning light will come on if an emissions-related fault is detected .

Checking for Spark

Two generations of OBD are used on the cars covered by this manual . See 100 Engine-General for OBD information .

Checking for spark is difficult on engines with distributorless ignition systems.

On-Board Diagnostics " 1992-1995 models . . . . . . . . . . . . . . . . . . . . . OBD I " 1996 and later models . . . . . . . . . . . . . . . . . . OBD II

Try Rmovng the plugs and inspecting for differences between them . A poor-firing plug may be wet with fuel and/or black and sooty, but not always . If a coil is not operating, the engine management system will electrically disable the fuel injector to that cylinder . The key is to look for differences between cylinders.

NOTE" On cars with OBD ti, specialized OBD 11 scan tool equipment must be used to access DTCs, either using the BMW special tool or a `generic" OBD 11 scan tool. " The OBD 11 fault memory (including an illuminated Check Engine light) can only be reset using the special scan tool. Removing the connector from the ECM or dísconnecting the battery will not erase the fault memory.

On 6-cylinder engines, an ignition coil is located directly above each spark plug .

WARNING If a spark test is done incorrectly, damage to the engine control module (ECM) or the ignition coil(s) may result.

Ignition coil, testing and replacing (4-cylinder engine) 1 . Disconnect main harness connector from coils:

" On M42 engine, remove plastic covering from coils and disconnect individual harness connectors . " On M44 engine, disconnect main harness connectorat end of coil pack . See Fig. 3.

Basic Troubleshooting Principies An engine that starts and runs indicates the ignition system is fundamentally working-delivering voltage to at least some of the spark plugs. A hard-starting or poor-running engine, however, may indicate ignition coil problems, cracked or deteriorated spark plug wires (4-cylinder engines only), and worn or fouled spark plugs. WARNING Inefficient combustion (rich air/fuel mixture) can cause the catalytic converter to overheat and plug. An overheated catalytic converter can also be a tire hazard. Fig . 3 .

Ignition coil pack for M44 engine (arrow). Coil harness connector shown at 1 .

IGNITION SYSTEM SERVICE

120-4

IGNITION SYSTEM

2. Check for battery voltage o cofs . If voltage is not present, check wire between terminal 15 and ignition switch . See Electrical Wiring Diagrams . " On M42 engine, connect digital multimeter between terminal 15(+) in each harness connector and ground . See Fig. 4. " On M44 engine, connect voltmeter between terminal 2 (15+) in connector and ground . Turn ignition on and check for voltage. See Fig. 5.

0 4a

11502

Fig. 4. Ignition coil harness connector terminal identification for M42 engine .

Table b. Ignition Coil Resistance (M42 Engine) Terminals (refer to Fig. 4.)

Resistance

Coil primary

1 (-) and 15 (+)

10 .4-0 .8 ohms

Coil secondary

N.A .

Table c. Ignition Coil Resistance (M44 Engine) Terminais (refer to Fig. 5.)

Resistance

Coil #1 primary

1 (-) and 2 (+)

0.4-0 .8 ohms

Coil #2 primary

6 (-) and 2 (+)

0.4-0 .8 ohms

Coil #3 primary

7 (-) and 2 (+)

0.4-0 .8 ohms

Coil #4 primary

5 (-) and 2 (+)

0.4-0 .8 ohms

Coil secondary

N.A .

N .A .

NOTE-

If a single coil ís faulty on M44 engines, the complete coil pack will have to be replaced.

Ignition coil, testing and replacing (6-cylinder engine) CAUTION-

Use a digital multimeter for the following tests.

1 . Remove plastic engine covers from top of engine by prying off nut covers and removing cover mounting nuts. See 113 Cylinder Head Removal and Installation . Fig. 5. Ignition coil harness connector terminal identification for M44 engine .

CAUTION-

The wiring to the coil (via the ignition switch 15+) is not fuse protected. Use care when testing this circuit.

2 . Disconnect harness connector from cof . Connect multimeter between terminal 15 (+) in connector and ground . See Fig. 6. 3. Turn ignition on and check for battery voltage. " If battery voltage is not present, check wire between terminal 15 and ignition switch . See Electrical Wiring Diagrams .

3. Turn ignition off. 4. Use a digital multimeter to test coil primary resistance . " On M42 engine, use Table b as a guide to check coil resistance . Make checks at each harness connector. " On M44 engine, use Table,c as a guide to check coil primary resistance .

5. Inspect coil housing for hairline cracks or leaking casting material . See Fig . 7. A leaky ignition coil may indicate a faulty ECM (engine control module). Check the ECM before installing a new coil .

IGNITION SYSTEM SERVICE

"mozo 11502

Fig. 6. Ignition coil harness connector terminal identification for 6cylinder engine .

IGNITION SYSTEM

120-5

Crankshaft Position/rpm Sensor

CAUTION -

The wiring to termina¡ 15 (+) of the coil (vía the ignition switch) is not fuse protected. Use care when testíng this circuit.

If the engine control module (ECM) does not receive a crankshaft position signal during cranking, the engine will not start.

4. Turn ignition off. 5. Use a multimeter to test coil primary resistance at coil terminals. See Table d.

On 1992-1995 (pre-OBD II) cars, the crankshaft position/rpm sensor is mounted on the front engine cover and reads the toothed vibration dampener wheel. See Fig. 8.

Table d. Ignition Coil Resistance (6-cylinder Engine) Terminals (refer to Fig. 4.)

Resistance

Coil primary

1 1 (-) and 15 (+)

X 0.4-0 .8 ohms

Coil secondary

l N.A.

N.A .

6. Remove coil and inspect coil housing for hairline cracks or leaking casting material . See Fig. 7. A leaky ignition coil may indícate a faulty engine control module (ECM) . Check ECM before installing a new coil .

Fig. 8. Crankshaft position/rpm sensor mounted at front of engine on 1992-1995 cars . (arrow). On 1996 and latee cars (OBD II compliant), the crankshaft position/rpm sensor is mounted in the left rear side of the cylinder block. The sensor reads a toothed wheel mounted to the end of the crankshaft . See Fig. 9.

811004

Fig. 7. Ignition coil being removed on 6-cylinder engine (M52 engine shown) . CA UTION-

" Note location of coil ground straps before coil removal; reinstall in the same location . " When replacing ignition coils, ensure that the replacement coil(s) are from the same manufacturer containing the same partlcode numbers. If individual coils with the correct specifications are not available, all coils should be replaced .

Fig. 9. Crankshaft position/rpm sensor toothed wheel mounted to rear of crankshaft OBD II compliant cars . The sensor is mounted in the left rear side of the cylinder block.

IGNITION SYSTEM SERVICE

120-6

IGNITION SYSTEM

Crankshaft position/rpm sensor, testing and replacing (front mounted) 1 . Disconnect sensor harness connector. 2. Using a digital multimeter, check resistance between terminals 1 and 2 in connector. See Fig. 10 .

3. Installation is reverse of removal. Use a new O-ring when installing sensor. Be sure wiring is rerouted in same orientation . Secure sensor using new wire ties. NOTEIt may be easier to remove the sensor working from the underside of the vehicle.

Camshaft Position (CMP) Sensor

The camshaft position (CMP) sensor is used by the engine management system for sequential fuel injection and knock control.

6502AGN56

Camshaft position (CMP) sensor, replacing (4-cylinder engine) 1 . Remove CMP sensor from top timing cover, just above coolant thermostat housing . See Fig. 11 .

Fig. 10 . Crankshaft position/rpm sensor connector.

Crankshaft positionlrpm sensor specifications " Coil resistance (approx.) terminais 1 and 2 . . . . . . . . . . . . . . 1280 ± 10% ohms " Air gap (sensor distance from toothed wheel) . . . . . . . . . . . . . 1 .0 ± 0.3 mm (0 .04 ± 0.01 in .) 3. If the resistance is not correct, the sensor is faulty and should be replaced . NOTE When installing the new sensor, be sure the wiring Is rerouted in the same orientation . Secure the sensor using new wire ties.

Tightening Torque " Crankshaft position/rpm sensor to mounting bracket . . . . . . . . . . . 5 t 1 Nm (62 t 9 in-lb)

Crankshaft position/rpm sensor, replacing (rear mounted) 1 . Disconnect sensor harness connector.

2. Locate sensor on rear left side of cylinder block. Remove sensor mounting bolt and remove sensor from cylinder block.

IGNITION SYSTEM SERVICE

Fig. 11 . Camshaft position sensor mounting bolt (arrow). M42 engine shown . 2. On M42 engines to 9/93 : Disconnect CMP harness plug just above oil filter housing. 3. On M42 from 9/93 and all M44 engines: Remove upper intake manifold as described in 113 Cylinder Head Removal and Installation . Then unplug CMP sensor harness connector below manifold . 4. Installation is reverse of removal . Use a new O-ring when installing sensor. Be sure wiring is rerouted in same orientation .

IGNITION SYSTEM Camshaft position (CMP) sensor, replacing (6-cylinder engine) 1 . Remove plastic cover from above fuel injectors. 2. Disconnect harness connector from VANOS solenoid and unscrew solenoid from VANOS control unit . Remove oil supply line from VANOS control unit . See 117 Camshaft Timing Chain . 3. Remove camshaft position (CMP) sensor from left front of cylinder head, next to top of oil filter housing .

120- 7

NOTE " On M52 engines, a single harness connects the two sensors to the main harness connector. The shorter cable lead fs for the knock sensor for cytinders 4, 5, and 6.

" Clean contact surface on engine block before fnstall ing knock sensors.

Tightening Torque " Knock sensor to cylinder block . . . . 20 Nm (15 ft . lbs .)

4. Disconnect CMP sensor harness from under intake manifold . 5. Installation is reverse of removal . Use a new O-ring when installing sensor. Be sure wiring is rerouted in same orientation . Tightening Torques " CMP sensor to cylinder head . . . . . . . . 5 Nm (3 .5 ft-Ib) " VANOS oil supply pipe to VANOS control unit . . . . . . . . . . . . . . 32 Nm (24 ft-Ib) " VANOS solenoid to VANOS control unit . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft-Ib)

Knock sensors, replacing Knock sensors are used on engines with Bosch DME M1 .7, Bosch DME M3 .3 .1, Bosch DME M5 .2, and Siemens MS 41 .1 engine management systems. The knock sensors are bolted to the left side of the cylinder block and monitor the combustion chamber for engine-damaging knock. If engine knock is detected, the ignition point is retarded accordingly via the engine control module . On 6-cylinder engines, the knock sensors are accessible after removing the intake manifold . On 4-cylinder engines, the upper section of the intake manifold should be removed to access the sensors. See Fig. 12 . Intake manifold removal and installation procedures are covered in 113 Cylinder Head Removal and Installation . CA UTION" Label knock sensor harness connectors before disconnecting them. The connectors must not be interchanged. Engine damage may result if the sensors are monitoring the wrong cytinders . " Note the installed angle of the knock sensor on the block before removing it. Reinstall the sensor in the same position. Be sure to use a torque wrench when tightening the sensor mounting bola

0012730

Fig. 12. Knock sensor mounting bolt on front left side of cylinder block . NOTEKnock sensor function Is monitored by the On-Board Diagnostic system. If a knock sensor is detected to be faulty, an appropriate diagnostic trouble code (DTC) may be stored in memory. See 100 Engine-General for information on retrieving DTCs.

Ignition Firing Order NOTE" Cylinder no. 1 is at the front of the engine .

Ignition Firing Order " 4-cylinder engines . . . . . . . . . . . . . . . . . . . . . .1-3-4-2 " 6-cylinder engines . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4

IGNITION SYSTEM SCHEMATICS Fig. 13 through Fig. 17 show ignition system schematics used on the engines covered by this manual .

IGNITION SYSTEM SCHEMATICS

120-8

IGNITION SYSTEM Battery voltage in run or start ( vía ignition switch terminal 15)

WIRING COLOR CODE

4.0 GN

1 .0 GN

1E 11

1 .0

Ign . coil cyl . 1

1 .0 GN

Gl Ign . coil cyl . 3

BK BR RD YL GN BL VI GY WT PK

Ign. coil cyI .

2 1 Y _ Y2

1.0 BR

" -

BLACK BROWN RED YELLOW GREEN BLUE VIOLET GREY WHITE PINK

Warning: Lethal voltage present

Ign. coil

k 3 cyl . 4

Battery voltage in run or start (vía main relay terminal 87)

1.0 BR 'V. 2.5 BR

5GN

I I t I

Tti

%ti

----V

.35

_ .35BK

.35

_%ti _

_ice_

56 power input

54 Power input

Engine Control Module (Bosch DME Ml .7)

U 15

13,11

_ __

'Y 1 Y

.35 BK35 VE

.35 YE

--------------------34

Powerinput 26

Mainrelaycontrol 27

Battery voltage at all times

I I 1

to Main relay (terminal 85)

N[INS Knock Sensor Knock Sensor (cyl .1-2) (cyl .3-4)

Camshaft Position Sensor

Crankshaftlrpm Position Sensor

Ground (RH rear of engine compartment, rear of shock tower)

0013087

Fig. 13 . Bosch DME M1 .7 ignition system circuit for M42 engine .

IGNITION SYSTEM SCHEMATICS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

IGNITION SYSTEM Battery voltage in run or start ( via ignition switch terminal 15) 2.5 GN

Warnin Lethal óltage present

I I I

^1 .5WT

--__

g ____-

50 __-_ ^1 .5RD

1 .0 YL

/ 1 .0 BL

^1 .5YL

^1 .5BL

WIRING COLOR CODE BK BR RD YL GN BL VI GY WT PK

Battery voltage in run or start (via main relay terminal 87)

120-9

BLACX BROWN RED YELLOW GREEN BLUE VIOLET GREY WHITE PINK

Battery voltage in run or start ( via ignition switch terminal 15)

/ 1 .0 RDNJT

___-_23 -___-_____--__--

Engine Control Module (Bosch DME M5 .2)

-____-___ 5 ____- i

54 Powerinput

power input

grounds

P owerinput Main relay control I 26 27 20 - -78 -- - - - 34 55 6 70 - 40 71 21 - -- - -- - - - - - -- - -- - -- - -- - -- -- - -- - - -- - -- - - - - - -- - -- - `135 BK

35 BK

11.1

From main relay terminal 87 (battery voltage in run or start Battery voltage at all times .35 BK /

¡3

/ .35 BK

to Main relay (terminal 85)

194

Knock Sensor Knock Sensor (cyl .3-4) (cyl.1-2)

Camshaft Position Sensor

Crankshaftirpm Position Sensor -_ Ground (RH rear of engine compartment, rear of shock tower)

Ground (RH rear of engine compartment, rear of shock tower)

0012721

Fig. 14. Bosch DME M5 .2 ignition system circuit for M44 engine .

lGNITION SYSTEM SCHEMATlCS

120-10

IGNITION SYSTEM WIRING COLOR CODE

Battery voltage in run or start ( via ignition switch terminal 15)

BK BR RD YL GN BL VI GY WT PK

" " -

BLACK BROWN RED YELLOW GREEN BLUE VIOLET GREY WHITE PINK

Battery voltage in run or start ( via main relay Battery voltage terminal 87) in run or start (via ignition switch terminal 15)

5GN

--------------------------------------------------------55

S5154

DME Control Module (Bosch DME M3.1)

power input

grounds 34---"-6

Power input

P ower Input 26

Main relaY control I1 27

1 .0 RD

Ground (rear of engine compartment, rear of passenger side shock tower)

Battery voltage at all times

.! BK

to Main relay (terminal 85)

.EBK

Camshaft Position Sensor

Crankshaftlrpm Position Sensor

Ground (RHrear of engine compartment, rear of passenger side shock tower)

Ground (RH rear of engine compartment, rear of passenger side shock tower) 11508

Fig. 15 . Bosch DME M3 .1 used on 1992 M50 engines (without VANOS) .

IGNITION SYSTEM SCHEMATICS

IGNITION SYSTEM Battery voltage in run or start ( via ignition switch termina¡ 15)

120-11 IMIRING COLOR CODE BK BR RD YL GN EL VI GY WT PK

4.0 GN

" -

BLAOK BROWN RED YELLOW GREEN BLUF VIOLET GREY WHITE PINK

Battery voltage Battery voltage in run or start in run or start ( via ignition switch ( via main relay terminal 15) terminal 87)

/1 so

1 I II 70

_ __

j\ si

I'1

56 Power input

54 Power input

Engine Control Module (Bosch DME M13.1)

1 I I

grounds Main relaY control I P ower input 27 26 17 28 43 16 -34---"-6 69____________________________________________

1 .0 RD

From main rela terminal 87 (battery voltage in run or start

.5 BR

Battery voltage at all times .5 YL

RER

Knock Sensor Knock Sensor (cyl.1-3) (cyl .4-6)

to Main relay (terminal 85)

.5 BK

Camshaft Position Sensor

Crankshaft/rpm Position Sensor

Ground (RH rear of engine compartment, rear of shocktower)

Ground = (RH rear of engine compartment, back side of shock tower) 11506a

Fig. 16 . Bosch DME M33.1 ignition system círcuit for 1993-1995 M50 engines with VANOS.

IGNITION SYSTEM SCHEMATICS

120-12

IGNITION SYSTEM Battery voltage in run or start ( via ignition switch terminal 15)

WIRING COLOR CODE BK BR RD YL GN BL VI GY WT PK

Warning. Lethal voltage present

Battery voltage in run or start (via ignitíon switch terminal 15)

BLACK BROWN RED YELLOW GREEN BLUE VIOLET GREY WHITE PINK

Battery voltage in run or start (via main relay terminal 87)

1 .0 BR 1 .08~1 4 .0BKIRD /1 .0BK/YL '10BK/BL 1D

'1 .03KIGN

10BKNI

!1 rl 1 .0 B~ ^ 1 .0 BK/RD ^ 1 .0 BK/BL n 1 .0 BK/GN ^ 1 .0 BKIYL 1 .0 BKIVI %~ r ------- --------------_____________----_______-_-____ 49 29 1 30 2 31 3 87 1 power input

54 Power input

I 1 1 Powerinput Mainrelaycontrol 1 1 57 38 73 1 _ _ _58 - _59_ _ _ 63 _ 40- _ - - - - 64 32 34 4 26 1- - - - - 83 - - 48 --- -43 - - -65- - 41 - _28 - - -- - --- - -- - --- - 1 1

Engine Control Module (Siemens MS 41 .1)

.5 Y1-

.5BKY .5GNY .5BRY

grounds n

.35BKY/Y35YY Y Y'. 75 .18R/

.35BKY1 1 .5YL-1

I t

Knock Sensor Knock Sensor (cyl . 1-3) (cyl . 4-6)

Battery voltage at all times

Crankshaftlrpm Position Sensor

Camshaft Position Sensor

Ground (RH rear of engine compartment, rear of shock tower)

Fig. 17. Siemens MS 41 .1 ignition system used on 1996 and later 6-cylinder engines.

IGNITION SYSTEM SCHEMATICS

to Main relay (terminal 85)

Z = Ground (RH rear of engine compartment, rear of shock tower)

0012731

BATTERY, STARTER, ALTERNATOR

121-1

121 Battery, Starter, Alternator GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121-1 CHARGING SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . .121-2 Charging System Quick-Check . . . . . . . . . . . 121-2 Static current draw, checking . . . . . . . . . . . . . 121-2

Voltage regulator, removing and ínstalling . . . 121-6 Alternator brushes, inspecting and replacing .121-7

..................

BATTERY SERVICE . . . . . . . . . . . . . . . . . . . . 121-3 Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . 121-3 Hydrometer Testing . . . . . . . . . . . . . . . . . . . . 121-3 Battery Open-Circuit Voltage Test . . . . . . . . . 121-4 Battery Load Voltage Test . . . . . . . . . . . . . . . 121-4 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . 121-4

STARTER SERVICE . . . . . . . . . . . . . . . . . . . .121-7 Starter Troubleshootíng 121-7 Starter, removing and installing (4-cylinder engine) . . . . . . . . . . . . . . . . . . . . 121-8 Starter, removing and installing (6-cylinder engine with manual transmission) . . . . . . . . . . . . . . . . . . 121-8 Starter, removing and installing (6-cylinder engine with automatic transmission) . . . . . . . . . . . . . . . . 121-9 Solenoid switch, removing and installing . . . . 121-10

ALTERNATOR SERVICE . . . . . . . . . . . . . . . Charging system, checking . . . . . . . . . . . . . . Alternator, removing and installing (4-cylinder engine) . . . . . . . . . . . . . . . . . . . . Alternator, removing and installing (6-cylinder engine) . . . . . . . . . . . . . . . . . . . .

TABLES a. Battery, Starter and Charging System Troubleshooting . . . . . . . . . . . . . . . . : . . . . . . . . . . . 121-2 b. Specific Gravity of Battery Electrolyte at 80°F (27°C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121-3 c. Open-Circuit Voltage and Battery Charge . . . . . . . . 121-4 d. Battery Load Test-Minimum Voltage . . . . . . . . . . . 121-4

121-4 121-4 121-5 121-6

GENERAL The charging system consists of a belt-driven alternator with integral voltage regulator and a battery mounted in the luggage compartment . Various versions of alternators, voltage regulators, starters, and batteries are used in the E36 cars. It is important to replace components according to the original equipment specification. Check with an authorized BMW dealer for specific application and parts information . WARNING " Weargoggles, rubbergloves, and a rubberapron when working around batteries and battery acid (electrolyte). " Battery acid contains sulfuric acid and can cause skin irritation and burning. ff acid is spilled on your skin or clothing, flush the area at once with large quantities of water. lf electrolyte gets into your eyes, flush them with large quantities of clean water for several minutes and call a physician .

CAUTION -

" Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii. " Disconnecting the battery cables may erase fault codes stored in control unit memory. " Always disconnect the negative () battery cable first and reconnect it last. Cover the battery post with an insulating material whenever the cable is removed. " After reconnecting the battery, the power window motors must be reinitialized. See 511 Door Windows . " Never reverse the battery cables . Even a momentary wrong connection can damage the alternator or other electrical components. " Battery cables may be the same color. Label cable before removing.

" Batteries that are being charged or are fully charged give off explosive hydrogen gas. Keep sparks and open flames away. Do not smoke.

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

121-2

BATTERY, STARTER, ALTERNATOR

CHARGING SYSTEM TROUBLESHOOTING

Static current draw, checking

Charging system diagnostics requires special test equipment . If the test equipment is not available, charging system fault diagnosis can be performed by an authorized BMW dealer or other qualified repair shop . A general troubleshooting guide is given in Table a.

If the battery discharges over time, there may be a constant drain or current draw on the battery. A small static drain on the battery is normal, but a large drain will cause the battery lo quickly discharge. Make a static current draw test as the first step when experiencing battery discharge.

Charging System Quick-Check

1 . Make sure ignition and al¡ electrical accessories are switched off.

As a quick-check, use a digital multimeter lo measure voltage across the battery terminals with the key off and then again with the engine running . The battery voltage should be about 12 .6 volts with key off and approximately 14.0 volts with the engine running. If the voltage does not increase when the engine is running, there is a fault in the charging system .

2. Disconnect battery negative (-) cable. CAUTIONPriorto disconnecting the battery, read thebattery disconnection cautions given at the front of this manual on paga viii. 3. Connect a digital ammeter between negative battery post and negative battery cable lo measure current. See Fig. 1 . Wait at least one minuta lo get an accurate reading.

NOTE-

The regulated voltage (engine running) should be between 13.5 and 14.5, depending on temperatura and operating conditions . If the voltage is higher than 14.8, the voltage regulator is most Mely faulty.

A range of about 0 lo 100 milliamps is normal, depending on the number of accessories that need constant power. A current of 400 milliamps (0 .4 amp) or more may indicate a problem.

Check for clean and tight battery cables . Check the ground cable running from the negative (-) battery terminal lo the chassis and the ground cable running from the engine lo the chassis. Check the alternator drive belt condition and tension.

Table a. Battery, Starter and Charging System Troubleshooting Symptom 1 . Engine cranks slowly or not at all, solenoíd clicks when starter is operated .

2. Battery will not stay charged more than a few days .

Probable Cause

4. Lights dim, light intensity varies with engine speed.

Correctiva Action

a. Battery cables loose, dirty or corroded. b. Battery discharged . c. Body ground strap loose, dirty or corroded. d. Poor connection at starter motor terminal 30 . e. Starter motor or solenoid faulty.

a. Clean or replace cables. See 020 Maintenance Program.

a. Short circuit draining the battery.

a. Test for excessive current drain with everything electrical in the vehicle off. b. Evaluate driving style. Where possible, reduce electrical con sumption when making short trips.

b. Short driving trips and high electrical drain on charging system does not allow battery to recharge. c. Drive belt(s) worn or damaged. d. Battery faulty. e. Battery cables loose, dirty or corrodad. f. Alternator or voltage regulator faulty.

3. Battery losing water.

1 a. Battery overcharging .

a. Drive belt(s) worn or damaged. b. Alternator or voltage regulator faulty. c. Body ground straps loose, dirty or corroded .

CHARGING SYSTEM TROUBLESHOOTING

b. Charge battery, test and replace if necessary. c. Inspect ground strap, clean, tighten or replace if necessary. d. Check connections, test for voltage at starter. Test for voltage at neutral safety or clutch interlock switch . e. Test starter.

c. Inspect or replace multi-ribbed belt(s) . See 020 Maintenance Program. d. Test battery and replace íf necessary. e. Clean or replace cables . See 020 Maintenance Program. f. Test alternator and voltage regulator.

1 a. Test voltage regulator for proper operation. a. Inspect or replace multi-ribbed belt(s). See 020 Maintenance Program. b. Test alternator and voltage regulator. c. Inspect ground straps, clean, tighten or replace as necessary.

BATTERY, STARTER, ALTERNATOR

121-3

noN~A

B9517

Fig. 1 . Electrical system static current draw being measured . To determine the circuit or component causing the problem, remove one Puse at a time until the current drops to a normal range.

BATTERY SERVICE The E36 uses a six-cell, 12-volt lead acid battery mounted in the luggage compartment. See Fig . 2. NOTEE36 convertible models require a special battery which is designed for constant vibratfon. A battery not designed for this will fail much earlier.

Battery capacity is determined by the amount of current needed to start the vehicle, and by the amount of current consumed by the electrical system . BMW batteries are rated by ampere/hours (Ah) and cold cranking amps (CCA) rating . The Ah rating is determined by the average amount of current the battery can deliver over time without dropping below a specified voltage. The CCA is determined by the battery's ability to deliver starting current at 0° F (-18° C) without dropping below a specified voltage.

Battery Testing Battery testing determines the state of battery charge . On conventional or low-maintenance batteries the most common method of testing the battery is that of checking the specific gravity of the electrolyte using a hydrometer . Before testing the battery, check that the cables are tight and free of corrosion . See Fig. 2.

Hydrometer Testing The hydrometer consists of a glass cylinder with a freely moving float inside. When electrolyte is drawn into the cylinder, the level to which the float sinks indicates the specific

Fig. 2. Battery in right side of luggage compartment . gravity of the electrolyte . The more dense the concentration of sulfuric acid in the electrolyte, the less the float will sink, resulting in a higher reading and indicating a higher state of charge). NOTE-

Electrolyte temperature affects hydrometer reading . Check the electrolyte temperature with a thermometer. Add 0 .004 to the hydrometer reading for every 10°F (6°C) that the electrolyte is above 80°F (27°C) . Subtract 0.004 from the reading for every 10°F (6°C) that the electrolyte is below 80°F (27°C) . Before checking the specific gravity of a battery, load the battery with 15 amperes for one minute . lf the battery is installed in the vehicle, this can be done by turning on the headlights without the engine running. Table b lists the percentage of charge based on specific gravity values . Table b. Specific Gravity of Battery Electrolyte at 80 °F (27°C) Specific gravity 1 .265 1 .225 1 .190 1 .155 1 .120

State of charge Fully charged 75% charged 50% charged 25% charged Fully discharged

The battery is in satisfactory condition if the average specific gravity of the six cells is at least 1 .225 . If the specific gravity is above this leve¡, but the battery lacks powerfor starting, determine the battery's senrice condition with a load voltage test, as described below. If the average specific gravity of the six cells is below 1 .225, remove the battery from the luggage compartment and recharge . If, after recharging, the specific gravity varies by more than 0.005 between any two celis, replace the battery.

CHARGING SYSTEM TROUBLESHOOTING

121-4

BATTERY, STARTER, ALTERNATOR

Battery Open-Circuit Voltage Test

Battery Charging

Before making the test, load the battery with 15 amperes for one minute with a battery load-tester or turn on the headlights for about one minute without the engine running .Then disconnect the battery negative (-) cable and connect a digital voltmeter across the battery terminals. Open-circuit voltage levels are given in Table c.

Discharged batteries can be recharged using a battery charger. The battery should be removed from the luggage compartment during charging .

If the open-circuit voltage ís OK but the battery still lacks power for starting, make a load voltage test . If the open-circuit voltage is below 12 .4 volts, recharge the battery and retest .

12 .4 V 12 .2 V

12 .0 V

11 .7 V or less

50% charged

CAUTION-

75% charged 25% charged

Fully discharged

" Battery electrolyte (sulfuric acid) can damage the car. If electrolyte is spilled, clean the area with a solution of baking soda and water. " Always allow a frozen battery to thaw before attempting to recharge it.

A battery load tester is required for a load voltage test . The test is made by applying a high resistive load to the battery terminals and then measuring battery voltage. The battery should be fully charged for the most accurate results. The battery cables must be disconnected before making the test. If the voltage is below that listed in Table d, the battery should be replaced . WARNING -

Always wear protective goggles and clothing when performing a load test.

Table d. Battery Load Test-Minimum Voltage (apply 200 amp load for 15 seconds) 80°F (27°C)

WARNING -

State of charge Fully charged

Battery Load Voltage Test

Ambient temperature

charger (6 amperes or less) to prevent battery damage caused by overheating .

Hydrogen gas given off by the battery during charging is explosive . Do not smoke . Keep open llames away from the top of the battery, and prevent elec trical sparks by turning off the battery charger before connecting or disconnecting it.

Table c. Open-Circuit Voltage and Battery Charge Open-circuit voltage 12 .6 V or more

Prolonged charging causes electrolyte evaporation to a lev

el that can damage the battery. It is best to use a low-current

Voltage 9.6 V

60°F (16°C)

9.5 V

40°F (4°C)

9.3 V

20°F (-7°C)

8.9 V

0°F (-18°C)

8.5 V

- Always disconnect both battery cables and remove battery from vehicle during battery charging. Do not exceed 16.5 volts at the battery.

ALTERNATOR $ERVICE Before checking the alternator and regulator, make sure the battery is fully charged and capable of holding a charge . Check that the battery terminals are clean and tight and the alternator drive belt is properly tensioned and not severely worn .

Charging system, checking CAUTION-

Do not disconnect the battery while the engine is running, . Damage to the alternator andlor engine electronic systems may result.

1 . Turn ignition key on . Check that the charge warning lamp comes on . NOTE-

If the warning light does not come on, repair any wiring or bulb faults before continuing to check the charging system .

ALTERNATOR SERVICE

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

BATTERY, STARTER, ALTERNATOR

121- 5

2. Remove cooling duct or terminal cover from rear of alternator.

2. Remove air cleaner upper section with mass air flow sensor.

3. Check for battery voltage between ground and terminal B+ at back of alternator. Then turn ignition on and check for battery voltage between terminal D+ and ground . See Fig. 3. lf voltage is not present at either point, check wiring for faults .

3. Remove terminal cover from rear of alternator. Discon nect wiring . 4. Remove drive belt from alternator pulley. See 020 Maintenance program. NOTE -

If reusing drive belt, mark direction of rotation on belt before removing.

5. On M44 engine with hydraulic belt tensioner: Remove tensioner idler pulley (upper roller) from alternator bracket. 6. Remove upper and lower mounting bolts and lift out alternator . See Fig. 4.

001 ¡987

Fig. 3. Terminal B+ is supplied battery voltage directly from the battery. Terminal D+ is supplied battery voltage via the charge warning bulb when the key is on or the engine is running. 4. lf no faults are found up to this point, test alternator output using a load tester. 5. If a load tester is not available, a crude output test can be done by running engine at about 2000 rpm and turning on electrical loads (fans, lights and rear window defroster, wipers) . With al¡ accessories on, battery voltage should be above 12 .0 VDC .

uJ S v~~

1i n

-12.22

Fig. 4. Alternator mounting bolts (arrows) .

Alternator, removing and installing (4-cylinder engine)

7. Installation is reverse of removal . Install drive belt as described in 020 Maintenance Program.

A replacement alternator should have the same rating as the original . Alternator manufacturer and ampere rating are normally marked on the alternator housing.

Tightening Torques " D+ vire to alternator (M6 nut) . . . . . . . 7 Nm (53 in-lb) " B+ wire to alternator (M8 nut) . . . . . . . 13 Nm (10 ft-Ib) " Pulley to alternator (M16 nut) . . . . . . . 60 Nm (44 ft-Ib)

1 . Disconnect negative (-) battery cable. CAUTION-

Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡.

ALTERNATOR SERVICE

121-6

BATTERY STARTER, ALTERNATOR

Alternator, removing and installing (6-cylinder engine) A replacement alternator should have the same rating as the original . Alternator manufacturer and ampere rating are normally marked on the alternator housing . 1 . Disconnect negative (-) battery cable.

CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

2. Remove alternator cooling duct and air filter housing assembly from car. Disconnect wiring from rear of alternator. 3. Remove radiator cooling fan and fan shroud . See 170 Radiator and Cooling System .

NOTE-

The radiator cooling fan nut (32 mm wrench) has lefthand threads .

NOTE-

If reusing drive belt, mark direction of rotation on belt before removing.

5. Remove upper and lower mounting bolts and lift out alternator. 6. Installation is reverse of removal. Note locating notches on tensioner idler pulley (upper roller) alternator bracket when installing pulley. Tightening Torques " D+ wire to alternator (M6 nut) . . . . . . . 7 Nm (53 in-lb) " B+ wire to alternator (M8 nut) . . . . . . . 13 Nm (10 ft-Ib) " Pulley to alternator (M16 nut) . . . . . . . 60 Nm (44 ft-Ib)

Voltage regulator, removing and installing 1 . Disconnect negative (-) cable from battery. 2. Remove alternator as described earlier. 3. Remove cooling duct from rear of alternator. See Fig. 6.

4. Remove alternator drive belt from alternator pulley. On engines with hydraulic belt tensioner, remove tensioner idler pulley (upper roller) from alternator bracket. See Fig . 5.

. .g-. . .

Alternator

Cooling duct 0012524

Fig . 6.

Alternator assembly and related parts .

4. Remove voltage regulator mounting screws and remove regulator from alternator. 5. Installation is reverse of removal. Clean brush contact surfaces in alternator and check brush length as described later. Fig. 5 . Pry off cover from tensioner and then lever tensioner clockwise to release belt tension . Remove upper roller (A) once belt ís removed .

ALTERNATOR SERVICE

BATTERY, STARTER, ALTERNATOR Alternator brushes, inspecting and replacing Regulator brushes are not available as replacement parts from BMW. Replacement brushes may be available from aftermarket sources, however. 1 . Remove voltage regulator as described above. 2. Clean brush contact sürfaces and measure brush protrusion . See Fig. 7.

121-7

STARTER SERVICE Starter Troubleshooting If the starter tucos the engine slowly or fails to operate when the ignition is in the start position, check the battery first. Inspect the starter wires, terminals, and ground connections for good contact. In particular, make sure the ground connections between the battery, the body and the engine are completely clean and tight. If no faults can be found, the starter may be faulty and should be replaced . NOTE -

" Starting in 1194, a factory-installed drive-away protection system, also referred to as EWS or EWS 11, was used on all E36 cars . This system prevenís operation of the starter when the system is engaged. See 515

Central Locking and Anti-theft .

" On cars with automatic transmission, a starter relay and a neutral safety switch are used to present the engine from starting in gear positions other than park or neutral. ff voltage is not present at terminal 50 with the key in the start position, check these components

To make the most accurate check of the battery cables and starter wiring, make a voltage drop test on the cables and wiring as described in 600 Electrical System-General . Fig. 7. Regulator brush protrusion (A). Voltage Regulator " Brush protrusion (minimum) . . . . . . . . . . 5 mm ( 1/4 in .) 3. To replace brushes, carefully and as quickly as possible, unsolder brush lead from brush holder termina¡, withdrawing brush from holder at same time . 4. Remove any traces of solder from brush holder terminal using solder wick.

Check for battery voltage at terminal 50 of the starter motor with the key in the start position . See Fig. 8. If voltage is not present, check the wiring between the ignition switch and the starter terminal . If voltage is present and no other visible wir ing faults can be found, the problem is most likely interna¡ in the starter motor.

Terminal 30

' \ / Terminal 30h

5. Fit spring into brush holder and inserí new brush . 6. Guide brush lead into terminal and solder into place. Check for free movement of brushes when solder cools. 7. Check brush slip rings in alternator for wear. Lightly clean slip rings using fine abrasive cloth. 8. Reinstall regulator and alternator.

0012518

Fig. 8. Typical starter wiring terminal identification . Large wire at terminal 30 is direct battery voltage. Smaller wire at terminal 50 operates starter solenoid via ignition switch .

STARTER SERVICE

121-8

BATTERY, STARTER, ALTERNATOR

1f the solenoid audibly cliicks but the motor does not turn, switch on the lights and tum the key to the start position . lf the lights go out while attempting to start, the battery cable may be loose or the starter may have a short circuit. If the lights stay on, the solenoid is most likely at fault.

Starter, removing and installing (4-cylinder engine) 1 . Disconnect negative (-) cable from battery. CAUTION-

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

Starter, removing and installing (6-cylinder engine with manual transmission) The starter on a 6-cylinder car with manual transmission is removed from below. 1 . Disconnect negative (-) battery cable. 2. Raise vehicle. 3. Remove reinforcing cross brace from under transmíssion, if applicable .

2. Remove guide tube for oil dipstick .

4. Remove cover from fuel filter and fuel lines on left side underneath car, if applicable . Detach fuel lines and harness connectors from retaining brackets, as necessary

3. Raise vehicle.

5. Disconnect wiring from starter.

WARNING Make sure the car ís stable and wefl supported at all times . Use a professional automotive lift or jack stands designed for the purpose. A floorjack is not adequate support.

4. Disconnect wiring from starter. 5. Remove top and bottom starter bolts. Bottom bolt must be removed from below car . Remove starter support bracket, if applicable . 6. Pull starter downward and turn until solenoid is at top, then remove from car. 7. >Check starter pinion gear and flywheel teeth for damage. 8. Installation is reverse of removal. Tightening Torques " Starter to engine block (M10 bolt) . . . 50 Nm (37 ft-lb) Wire to terminal 50 (M6 nut) . . . . . . . . 6 Nm (53 in-lb) " Wire to terminal 30 (M8 nut) . . . , . . : . 12 Nm (9 ft-Ib)

STARTER SERVICE

6. Loosen and remove bolts and nuts fastening starter to transmission bell housing and/or engine block. Remove starter support bracket. 7. Remove starter from below. 8. Check starter pinion gear and flywheel teeth for damage. 9. Installation is reverse of removal . Tightening Torques " Re¡nforcing cross brace to chassis (M10) . . . . . . . . . . . . . . . . . 42 Nm (31 ft-Ib) " Starter to engine block (M10 bolt) . . . 50 Nm (37 ft-Ib) " Support bracket to starter (M5 nut) . . . 5 Nm (44 in-lb) " Support bracket to engine block (M10 bolt) . . . . . . . . . 47 Nm (35 ft-Ib) " Wire to terminal 50 (M6 nut) . . . . . . . . . 6 Nm (53 ín-Ib) " Wire to terminal 30 (M8 nut) . . . . . . . . . 12 Nm (9 ft-lb)

BATTERY, STARTER, ALTERNATOR

121- 9

Starter, removing and installing (6-cylinder engine with automatic transmission) The starter on a 6-cylinder car with automatic transmission ís removed from above. It is necessary to remove the íntake manifold and disconnect a number of electrical harness connectors. 1 . Disconnect negative (-) battery cable. 2. Remove air plenum from rear of engine compartment. See 640 Heating and Air Conditioning . 3. Remove top engine covers. See Fig. 9.

Fig. 10. Fuel injection harness (A) and ignition coíl harness connectors (B) being lifted off engine to be placed at base of windshield . M50 engine shown. Other 6-cylinder engines are similar. 8. Loosen and remove bolts and nuts fastening starter to transmission bell housing and/or engine block. Remove starter support bracket.

Fig. 9. Remove top engine cover by prying out plugs and removing nuts (A). Make sure rubber insulators (B) on either side of large cover do not fall off during cover removal. 4. Remove ignition coil harness connectors . Remove ground connection at front of cylinder head . 5. Remove two retaining bolts and lift off fuel injector harness connector strip. Carefully fold away all harnesses toward right side of engine compartment and place at base of windshield . See Fig. 10 . 6. Remove intake manifold . See 113 Cylinder Head Removal and Installation . 7. Disconnect wiring from starter.

Fig. 11 . Starter wiring terminals and support bracket (arrow). Intake manifold has been removed.

STARTER SERVICE

121-1 O

BATTERY, STARTER, ALTERNATOR

9. Remove starter from above. 10 . Check starter pinion gear and flywheel teeth for damage. 11 . Installation is reverse of removal. Tightening Torques " tntake manifold to cylinder head M7 nut . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (11 ft-Ib) M8 nut/bolt . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft-Ib) " Starter to engine block (M10 bolt) . . . 50 Nm (37 ft-Ib) " Support bracket to starter (M5 nut) . . . 5 Nm (44 in-lb) " Support bracket to engine block (M10 bolt) . . . . . . . . . 47 Nm (35 ft-Ib) " Wire to terminal 50 (M6 nut) . . . . . . . . 6 Nm (53 in-lb) " Wire to terminal 30 (M8 nut) . . . . . . . . 12 Nm (9 ft-Ib)

Solenoid switch, removing and installing 1 . Remove starter as described above. 2. Remove cover from solenoid switch . 3. Disconnect fieid winding strap between starter motor and solenoid switch . NOTEThe condition of the field winding strap is critical . If it is damaged, bumed or partially melted through, a new or rebuilt starter motor is needed.

4. Remove solenoid switch mounting screws, and sepa, rate solenoid from starter. See Fig. 12 . CAUTION-

When installing fieid winding strap to starter, position it so that it does not contact the starter body.

STARTER SERVICE

131~184

Fig. 12 . Starter solenoid mounting screws (arrows) are tight . Use en impact screwdriver to loosen the screws . 5. Installation is reverse of removal. Lubricate solenoid pistos with light grease . Tightening Torque " Field winding strap to starter (M8) . . . . 12 Nm (9 ft-Ib)

FUEL INJECTION

130-1

130 Fuel i njection GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130-2 Principles of Operatinn . . . . . . . . . . . . . . . . . . 130-2 Basic Engine Settings . . . . . . . . . . . . . . . . . : . 130-3 DISA (Dual Resonance Intake System) . . . . . 130-3 On-Board Diagnostics (OBD) and Fault Diagnosis . . . . . . . . . . . . . . . . . . . 130-4 SecondaryAir Injection . . . . . . . . . . . . . . . . . . 130-5 Warnings and Cautions . . . . . . . . . . . . . . . . . . 130-6 ELECTRICAL CHECKS AND COMPONENT TESTING . . . . . . . . . . . . . . . . 130-7 Main relay, testing . . . . . . . . . . . . . . . . . . . . . . 130-7 Fuel pump relay, testing . . . . . . . . . . . . . . . . . 130-7 Oxygen sensor, testing (Bosch systems only) 130-8 FUEL DELIVERY TESTS . . . . . . . . . . . . . . . 130-9 Operating fuel pump for tests . . . . . . . . . . . . . 130-9 Relieving fuel pressure and connecting fuel pressure gauge . . . . . . . . . 130-10 Residual fuel pressure, testing . . . . . . . . . . . 130-10 Fuel pressure regulator response to engine load, testing . . . . . . . . . . . . . . . . 130-11 Fuel rail and injectors, checking . . . . . . . . . . 130-11 Fuel rail and injectors, replacing . . . . . . . . . 130-12 Fuel Pressure Regulator . . . . . . . . . . . . . . . . 130-13 Fuel pressure regulator, replacing (fuel rail mount) . . . . . . . . . . . . . . . . . . . . . 130-13 Fuel pressure regulator, replacing (under car mount) . . . . . . . . . . . . . . . . . . . 130-14 BOSCH DME M1 .7 COMPONENT TESTS AND REPAIRS . . . . . . . . . . . . . . . . 130-14 Air flow sensor, testing and replacing . . . . . . 130-14 Engine coolant temperature (ECT) sensor, testing and replacing . . . . . . . . . . . 130-15 Throttle position sensor (TPS), testing and replacing . . . . . . . . . . . . . . . . . 130-16 Idle speed control valve, testing and replacing . . . . . . . . . . . . . . . . . 130-16 BOSCH DME M3.1 AND M33.1 COMPONENT TESTS AND REPAIRS . . . 130-17 Mass Air Flow Sensor . . . . . . . . . . . . . . . . . .130-17 Mass air flow sensor (hot wire), testing and replacing . . . . . . . . . . . . . . . . . 130-17 Mass air flow sensor (hot film), testíng and replacing . . . . . . . . . . . . . . . . . 130-18 Engine coolant temperature (ECT) sensor, testing and replacing . . . . . . . . . . . 130-18

Intake air temperature (IAT) sensor, testing and replacing . . . . . . . . . . . . . . . . . . 130-19 Throttle position sensor (TPS), testing and replacing . . . . . . . . . . . . . . . . . .130-19 Idle speed control valve, testing . . . . . . . . . . 130-20 Idle speed control valve, replacing . . . . . . . . 130-21 BOSCH DME M5.2 COMPONENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 130-21 Mass air flow sensor, replacing . . . . . . . . . . . 130-22 Engine coolant temperature (ECT) sensor, replacing . . . . . . . . . . . . . . . . . . . . 130-22 Intake air temperature (IAT) sensor, rep lacin . . . . . . . . . . .g . . . . . . . . . . . . . . . .130-22 Throttle poson sensor (TPS) , replacing . . . 13022 Idle speed control valve, replacing . . . . . . . . .130-23 SIEMENS MS 41 .1 COMPONENT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . .130-23 Mass air flow sensor, replacing . . . . . . . . . . .130-25 Engine coolant temperature (ECT) sensor, replacing . . . . . . . . . . . . . . . . . . . .130-25 Intake air temperature (IAT) sensor, replacing . . . . . . . . . . . . . . . . . . . . . . . . . . .130-25 Throttle position sensor (TPS), replacing . . . 130-26 Idle s peed control valve, rep lacin g . ' ' ' . . . . ' 130-26

ECM PIN ASSIGNMENTS . . . . . . . . . . . . . . . 130-26 Engine control module (ECM), accessing . . . 130-26 TABLES a. Engine Management System Variants . . . . . . . . . .130-2 b. Mass Air Flow Sensor Variants . . . . . . . . . . . . . . . .130-2 c. Fuel Pressure Specifications . . . . . . . . . . . . . . . . . 130-11 d. Engine Coolant Temperature Sensor or Intake Air Temperature Sensor Test Values (DME 1 .7) . . . . 130-15 e. Throttle Position Sensor Tests (DME 1 .7) . . . . . . .130-16 f . Engine Coolant Temperature Sensor or Intake Air Temperature Sensor Test Values (DME 3.1/3.3.1)130-19 g. Throttle Position Sensor Tests (DME 3.1/3.3.1) . .130-20 h. ECM Pin Assignment-Bosch DME M1 .7 . . . . . . . .130-28 i. ECM Pin Assignment-Bosch DME M3.1 . . . . . . . .130-30 j . ECM Pin Assignment-Bosch DME M3.3.1 . . . . . .130-32 k. ECM Pin Assignment-Bosch DME M5.2 . . . . . . . . 130-34 I. ECM Pin Assignment-Siemens DME MS 41 .1 . . . 130-36

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

130-2

FUEL INJECTION

GENERAL This repair group covers fuel injection system component testing and repair . Special equipment is necessary for some of the procedures given in this repair group. If you do not have the equipment required to do the job, it is recommended that these repairs be left to an authorized BMW dealer. The BMW dealer is equipped with sophisticated diagnostic test equipment that is capable of quickly pinpointing hard-to-find fuel injection problems .

NOTE-

" Wiring diagrams for the engine management system, can be found at the rear of the manual under Electri-

cal Wiring Diagrams .

" For ignition system repair information, see 120 Igni-

Fig. 1 . OBD II diagnostic connector locatíon .

" For fuel supply system testing and repair, see 160 Fuel Tank and Fuel Pump.

The engine control module (ECM) uses electrical signals from the mass airflow sensor, the air and coolant temperature sensors, the crankshaft position/rpm sensor, the knock sen sors and the oxygen sensors as the primary inputs to electronically control fuel delivery and ignition timing .

tion System .

Principies Of Operation There are five versions of engine management systems used on the E36 cars . Each has the same basic components and operating principles. The most notable difference is that 1996 and later cars use a sophisticated OBD II-compliant system. See Table a. Table a. Engine Management System Variants Engine code/year 4-cy1inder

M42 (1 .8 I) 1992-1995 M44 (1 .91) 1996-1998

6-cylinder M50 1992 (2 .5 I) 1993-1995 (2 .5 I) M52 1996-1998 (3281- 2 .8 I) 1998 (3231 - 2 .5 I) M-Power S50US (M3 - 3 .01) 1995 S52US (M3 - 3.21) 1997-1998

1 System Bosch DME Ml .7 ~ Bosch DME M5 .2 (OBD II) Bosch DME M3 .1 Bosch DME M3 .3 .1 (VANOS) Siemens MS 41 .1 (OBD II) Siemens MS 41 .1 (OBD II) Bosch DME M3 .3 .1 Siemens MS 41 .1 (0131) 11)

NOTE- Descriptions and procedures in the first part of this re-

pairgroup refer to all the various engine management systems .

" Particulars of each fuel injection system are treated in separate sections in the second part of this repair group . " The 16-pin OBD 11 diagnostic connector is located on the lower left dash panel. See Fig. 1 .

The fuel injection system is completely electronic in operation . Air flow is measured electronically via a mass air flow sensor and additional sensors supply information about engine operating conditions . The ECM calculates the amount of fuel needed for the correct air-fuel ratio and actuates the fuel injectors accordingly . The amount of fuel metered to the engine is determined by how long the injectors are open . Air intake. Air entering the engine passes through a pleated paper air filter in the air cleaner. Intake air volume or mass is then measured by a mass air flow (MAF) sensor . In al¡ except the vane type sensor (DME M1 .7), a reference current is used to heat a thin wire or film in the sensor when the engine is running. The current used to heat the wire/film is electronically converted into a voltage measurement corresponding to the mass of the intake air. Table b. Mass Air Flow Sensor Variants System

Al r flow sensor type

Bosch DME M1 .7

Vane (volume sensor)

Bosch DME M3 .1

Hot wire (mass sensor)

Bosch DME M3 .3.1

Hot film (mass sensor)

Bosch DME M5 .2

Hot film (mass sensor)

Siemens MS 41 .1

Hot film (mass sensor)

NOTE-

On cars equipped wíth traction control, an additional throttle valve is controlled by an electronic throttle actuator (motor) . This valve is used for engine speed inter vention. Repair information for this system is not covered here due to the special electrical testing equipment required to service it.

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

FUEL INJECTION Fuel metering . The ECM meters fuel by changing the opening time (pulse width) of the fuel injectors. To ensure that injector pulse wídth is the only factor that determines fuel metering, fuel pressure is maintained by a fuel pressure regulator. The injectors are mounted lo a common fuel supply called the fuel rail . The ECM monitors engine speed to determine the duration of injector openings . Other signals to the ECM help determine injector pulse time for different operating conditions . A temperature sensor signals engine temperature for mixture adaption . A throttle position sensor signals throttle position . The exhaust oxygen sensor(s) signal information about combustion efficiency for control of the air-fuel mixture. 1992 to 1995 engines are equipped with a single sensor . 1996 and later (OBD II) engines are equipped with an oxygen sensor before and one after each catalytic converter. For example, the M52 engine is equipped with four oxygen sensors. Idle speed control. ldle speed is electronically controlled viathe idle speed control valve, which maintains idle speed by bypassing varying amounts of air around the closed throttle valve. Idle speed is not adjustable . Knock (detonation) control. Knock sensors monitor and control ignition knock through the ECM. The knock sensors function like microphones and are able to convert mechanical vibration (knock) into electrical signals. The ECM is programmed to react to frequencies that are characteristic of engine knock and adapt the ignition timing point accordingly. See 120 Ignition System for further details.

NOTE-

The 1992 M50 engine is not equipped with knock sensors. All other engines are equipped with two knock sensors.

Basic Engine Settings Idle speed, idle mixture (%CO), and ignition timing are not adjustable . The adaptive engine management system is designed to automatically compensate for changes in engine operating conditions, although the adaptive range is limited. Once these limits are exceeded, driveability problems usually become noticeable.

NOTE-

lf the system adaptive limits are exceeded, the Check Engine light will most likely come on, indicating an emissions- related fault For Check Engine light diagnostics, see 100 Engine-General .

130-3

The engine management system compensates automatically for changes in the engine due to age, minor wear or small problems, such as a disconnected vacuum hose . As a result, idle speed and mixture do not need lo be adjusted as part of routine maintenance.

NOTE-

Poordriveabilitymaybe encountered when the batteryis disconnected and reconnected. when the battery is disconnected, the adaptive memory is lost The system will readaptafterabout ten minutes of drfving.

DISA (Dual Resonance Intake System) The E36 4-cylinder engine is equipped with a dual intake runner system, termed DISA . DISA offers the advantages of both short and long intake pipes. Long intake runners are most useful at low to medium engine rpm for producing good torque characteristics. Short intake runners produce hígher horsepower at hígher engine speeds .

NOTE-

The term DISA comes from the German words Differenzierte Sauganlage, and can roughlybe translated as "differing intake manifold configuration ." See 100 EngineGeneral foradditional information on DISA operation .

Manifold construction : The intake manifold is a two-piece metal construction, with a pair of runners in the top section and four runners in the lower section. A butterfly valve is installed in the lower section, enabling the DISA solenoid to isolate one pair of runners from the other pair. See Fig. 2. Operation. With the DISA butterfly valve closed, the pipes in the top half of the manifold act together with the ram air pipes in the lower half to produce a single, long air intake pipe for each cylinder . See Fig. 3. The column of aír oscíllating in this combined pipe significantly increases engine torque in the medium rpm range. Above approximately 4,800 rpm, the butterfly valve between the intake air pipes for the two cylinder groups is opened . The shorter pipes in the lower manifold section now become the main suppliers of ram airto the cylinders, yielding greater power at the upper end of the engine rpm range. See Fig. 4. Control components . The DISA butterfly valve is actuated electro-pneumatically via the engine control module (ECM) . The valve begins to open as engine speed rises aboye 4,840 rpm and closes below 4,760 rpm. The action of the valve is deliberately delayed to prevent it from opening and closing repeatedly within a short time .

GENERAL

130- 4

FUEL INJECTION

Main Relay

Fig . 2. DISA system components . DISA is controlled via the engine control module (ECM) .

On-Board Diagnostics (OBD) and Fault Diagnosis Poor driveability may have a variety of causes . The fault may He with the ignition system, the fuel system, parts of the emission control system, or a combination of the three . Because of these interrelated functions and their effects on each other, it is often difficult to know where to begin looking for problems . Fig . 3. DISA manifold runners with butterfly valve closed for low rpmhigh torque operation .

For this reason, effective troubleshooting should always begin with an interrogation of the On-Board Diagnostic (01313) system . The OBD system detects certain emissions-related engine management malfunctions . When faults are detected, the OBD system stores a Diagnostic Trouble Code (DTC) in the system ECM . In addition, the Check Engine warning light will come on if an emissions-related fault is detected . Two generations of OBD are used on the cars covered by this manual . See 100 Engine-General for OBD I information and fault codes .

yje q Fig. 4.

0012734

DISA manifold runners with butterfly valve open for high rpmhigh power operation .

GENERAL

On-Board Diagnostics " 1992-1995 models . . . . . . . . . . . . . . . . . . . . . OBD I " 1996-1998 models . . . . . . . . . . . . . . . . . . . . . OBD II

FUEL INJECTION The fuel injection systems used on the 1996 and later cars covered bythis manual are OBD II compliant. This system is incorporated into both the Bosch M5 .2 (M44 engine) and the Siemens MS 41 .1 (M52/S52US engine) engine management systems. OBD II systems use sophisticated diagnostic software capable of recognizing and electronically storing hundreds of DTCs in the system ECM. DTCs can only be accessed using special scan tool test equipment. The BMW dealer is equipped with the specialized OBD II scan tool to quickly and efficiently locate engine management problems . Alternately, a "generic" scan tool can be used to access OBD II fault information . NOTE" At the time this manual went to press, generic scan tools were not widely available for BMW vehicles. The generic sean tool is a specialized tool that plugs into a standardized OBD 11 connector on 1996 and later passenger vehícles built for sale in the US.

130-5

Secondary Air Injection All OBD II 6-cylinder engines are equípped with a secondary air injection system . In addition, beginning in January 1997, the M44 engine was classified as a TLEV (Transitional Low Emission Vehicle) engine and is also equipped with secondary air injection. Typical components of the secondary air injection system are depicted in Fig. 5. Secondary air injection uses an electric pump to pump fresh air finto the exhaust system upstream of the catalytic converter during engine warm-up. By providing extra oxygen to the unburned fuel in the exhaust, hydrocarbons oxidize and carbon monoxide combines with oxygen to form carbon dioxide and water. The air injection pump stops within a specified timed intenral .

" The OBD 11 fault memory (including an illuminated Check Engine light) can only be reset using the special scan tool. Removing the connector trom 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 .

0 ®o oG00 0G~ 0

0 0

o 0

1 . Secondary air pump 2. Electric solenoid valve 3. One-way check valve 4. Intake manifold 5. Exhaust manifolds 6. Secondary air check-valve

,1--

,, ~

1111111 in

0013120

Fig. 5. Components of 6-cylinder secondary air injection system . 4cylinder system is similar.

GENERAL

130-6

FUEL INJECTION

Warnings and Cautions For personal safety, as well as the protection of sensitive electronic components, the following warnings and cautions should be adhered to when working on the engine management system . WARNING " The ignition system produces high voltages that can be fatal. Avoid contact with exposed terminals . Use extreme caution when working on a car with the ignition switched on or the engine running. " Do not touch or disconnect any high voltage cables from the coils or spark plugs while the engine is running or being cranked by the starter. " Connect and disconnect the DME system wiring and test equipment leads only when the ignition is switched off. " Gasoline is highly flammable and fts vapors are explosive. Do not smoke or work on a car near heaters or other fire hazards when diagnosing and repalring fuel system problems. Have a tire extinguisher avaílable in case of an emergency. " When working on an open fuel system, wear suitable hand protection, as prolonged contact wfth fuel can cause illnesses and skin disorders. " Renew fuel system hoses, clamps and O-rings any time they are removed. " Before making any electrical tests that require the engine to be cranked using the starter, disable the ignition system as described in 120 Ignition System .

CAUTION" Prior to disconnecting the battery, read the battery disconnectinn cautions given at the front of this manual on page vifi. " Do not connect any test equipment that delivers a 12-volt power supply to terminal 15 (+) of the ignition coil. The current flow may damage the ECM. In general, connect test equipment only as speclfied by BMW, this manual, or the equipment maker. " Only use a digital multlmeter for electrical test. " Only use an LED test light for quick tests. " Disconnecting the battery may erase fault code(s) stored in memory. Check for fault codes prior to disconnecting the battery cables. ff the Check Engine light ís illuminated, see 100 Engine-General for DME fault code information. ff any other system faults have been detected (indicated by an illuminated warning light), see an authorized BMW dealer. Additional systems with self-diagnostic capabilities include, ABS (Antilock brakes), SRS (Airbags), EML and ASC+T and AST (Traction Control) . " Do not run the engine wfth any of the spark plug wires dlsconnected. Catalytic converter damage may result. " Always wait at least 40 seconds after turning off the ignition before removing the engine control module (ECM) connector. ff the connector is removed before this time, residual power in the system relay may damage the control module . " Cleanliness is essential when working on an open fuel system . Thoroughly clean fuel line connections and surroundlng areas before loosening . Avoid moving the car. Only fnstall clean parts. " Fuel system cleaners and other chemical additives other than those specifically recommended by BMW may damage the catalytic converter, the oxygen sensor or other fuel supply components .

GENERAL

FUEL INJECTION ELECTRICAL CHECKS AND COMPONENT TESTING

130-7

87 851

Main relay, testing

186 30

The main relay is energized via the engine control module and supplies plus (+) power to the many of the engine management components and subsystems, including the fuel pump relay. If this relay is faulty, the engine will not start.

1 . With ignition off, remove main relay. See Fig. 6. Fuel

iommooommmoi

DME

87661

sensor

Fig. 7. Check for battery voltage at main relay terminals 30 and 86 . Voltage should be present at all times.

~ """

4. With ignition on and relay installed, check for battery voltage at terminals 87 . " If battery voltage is present, relay has energized and is functioning correctly. " lf battery voltage is not present and al¡ earlier tests are OK, relay is faulty and should be replaced .

0013034)

Fig. 6. Engine management relays in the power distribution box, left rear of engine compartment . CA UTION-

Relay positions can vary. Be sure to confirm relay position by identífyíng the wiring in the socket using the wiring diagrams found at the rear of this manual.

2. Check for voltage at terminal 30 and terminal 86 of re¡ay socket . See Fig. 7. " If battery voltage is present continue testing " lf battery voltage is not present at either point, check large red wire in relay socket . See Electrical Wiring Diagrams . NOTE-

The wiring to terminals 85 and 86 in the main relay may be reversed. Electrically, the relay functions either way. lf voltage ís not present at terminal 86, check for voltage at terminal 85.

3. Reinstall relay and turn ignition on . Gain access to underside of relay socket and check for ground at terminal 85 (brown wire). " lf ground is present continue testing. " If ground is not present, signal from ECM is missing. Check wire between ECM and relay. If no faults can be found, ECM may be faulty.

Fuel pump relay, testing The fuel pump relay is located in the power distribution box. Refer to Fig. 6. The ECM supplies power to the coil side of the fuel pump relay. During starting, the fuel pump runs as long as the ignition switch is in the start position and continues to run once the engine starts . If the relay ís faulty the fuel pump will not run . 1 . Remove fuel pump relay from its socket . 2. With key off, check for battery voltage at socket terminal 30 . See Fig. 8. 3. With ignition key in start position check for battery voltage at terminal 86 . 4. With ignition key, use digital multimeter to check for ground at terminal 85 . NOTE-

The ground at terminal 85 is switched by the ECM. The ECM hamess must be connected to check the switched ground connection.

5. If no faults are found up to this point, test fuel pump operation as described in 160 Fuel Tank and Fuel Pump .

ELECTRICAL CHECKS AND COMPONENT TESTING

130-8

FUEL INJECTION

0013135

Fig. 8. Fuel pump relay terminal identification .

Oxygen sensor, testing (BOSch systems only)

Fig . 9. Oxygen sensor location (arrow) ahead of catalytic converter. 3181 model with M42 engine shown. 1 . Peel back rubber boot on oxygen sensor electrical harness connector (car wiring side). With connector attached to sensor, connect digital voltmeter to pins 1 and 2 in rear of connector. See Fig. 10 .

CAUTION-

" The information in this section applies to Bosch engine management systems only. " The Siemens MS 41 .1 system uses resistive-type oxygen sensors. This sensor uses a 5-volt reference signal input and the output to the ECM varees from 1-5 volts, in stepped increments based on oxygen content in the exhaust.

NOTE-

" On pre-08D 11(1992-1995) cars, there is one oxygen sensor mounted upstream of the catalytic converter(s) in the exhaust pipe . See Fig . 9. " On OBD 11 cars (1996-1998) cars, there is one oxygen sensor before and one after each catalytic converter. " On M52 and S52US engines, the front pair of oxygen sensors are installed in the exhaust manifolds.

The oxygen sensor provides an input voltage signal (0-1 VDC) to the ECM based on the oxygen content in the exhaust gas. TO generate voltage, the sensor temperature must exceed 575°F (300°C). Therefore it ís electrically heated . NOTE-

" The test given below is not a conclusive test of oxygen sensor efficiency and does not test how quickly the oxygen sensor can react to changing conditions.

" Pin numbers and wire colors can vary. Always check the wiring diagrams to conflrm wire color and pin assignment.

ELECTRICAL CHECKS AND COMPONENT TESTING

1 . Black (ground)

2 . Grey (signal)

3. White (heater circuit) 4. White (heater circuit) 0013189

Fig. 10 . Oxygen sensor connectorterminal identification (sensorsede). Terminals numbers are molded into connector. 2. Start engine . Oxygen sensor should start to output a fluctuating voltage within a short period . If voltage is incorrect, turn engine off and check preheater circuit as described below. WARNING Exhaust manifolds and pipes can be hot enough to cause serious burns. Wear suitable heavy gloves and other appropriate protection.

FUEL INJECTION Oxygen Sensor " Voltage at ¡dle . . . . . . . . . . . 0.2 to 0.8 VDC, fluctuating

NOTE-

To check sensor response to lean and rich mixtures, createenairleak, orpull vacuumhoseofffue¡ pressure regulator to increase fuel pressure .

3. Separate sensor harness connector from sensor. Check for battery voltage between terminals 3 and 4 (green wire and brown wire) in main wiring harness side of connector with engine running. If voltage is not present, check oxygen sensor heater relay. See 610 Electrical Component Locations. 4. Check heater element resistance between terminals 3 and 4 in sensor side of connector. If element is electrically open (no continuity), replace sensor.

NOTE-

The oxygen sensor heater relay is mounted in the main power distributfon box in the left rear of the engine compartment. Refer to Fig . 6. The heater relay is energized wíth positive (+) battery voltage from the main relayand a switched ground from the ECM. See Electrical Wir-

ing Diagrams .

5. ¡f oxygen sensor doesn't produce a fluctuating voltage and preheater circuit is OK, replace sensor.

NOTE-

If not already applied, coat the oxygen sensor threads with an anti-seize compound before installation. Do not get the compound on the sensor tip.

Tightening Torque " Oxygen sensor to exhaust pipe . . . . . 55 Nm (41 ft-Ib)

130-9

FUEL DELIVERY TESTS Checking fuel delivery is a fundamental part of troubleshooting and diagnosing the engine management system . Fuel pressure directly influences fuel delivery . An accurate fuel pressure gauge will be needed to make the tests. There are three significant fuel delivery values to be measured: " System pressure-created by the fuel pump and maintained by the pressure regulator. " Fuel delivery volume-created by the fuel pump and affected by restrictions, such as clogged fuel filter. " Residual pressure-the pressure maintained in the closed system after the engine and fuel pump are shut off. Procedures for measuring the first two quantities are described in 160 Fuel Tank and Fuel Pump . Residual fuel pressure is checked using the procedure detailed later in this group.

Operating fuel pump for tests To operate the fuel pump for testing purposes without havíng to run the engine, the fuel pump relay can be bypassed to power the pump directly. Fuel pump relay location is shown in Fig. 6. To run the fuel pump, remove the fuel pump relay and connect the socket for relay terminal 30 to the socket for relay termina¡ 87 with a fused jumper wire . After completing the tests, remove the jumper wire . CAUTION" Relay locations may vary. Use care when identifying relays and making electrical checks at the fuselrelay panel. See 610 Electrical Compo nent Locations for additional relay information . " The fuel pump relay has a 1 .5 mm2 red wire at terminal 30 in the relay socket. Terminal 87 has a 1 .5 mm2 greenlviolet wire . See Electrical Wiring Diagrams for additional wiring information .

NOTE-

The jumper wire should be 1 .5 mm2 (14 ga.) and include an in-line tuse holder with a 15 amp tuse. To avoid fuselrelay panel damage from repeated connecting and disconnecting, also include a toggle switch . A heavy-duty jumper, BMW tool no. 61 3 050, is also available from an authorized BMW dealer.

FUEL DELIVERY TESTS

130- 1 0

FUEL INJECTION

Relleving fuel pressure and connecting fuel pressure gauge

On OBD II 6-cylinder engines, the fuel lines use a special locking fitting . Use BMW special tool 16 1 050 to release the fittings and connect the fuel gauge. See Fig. 12 .

To prevent fuel from spraying on a hot engine, system fuel pressure should be relieved before disconnecting fuel lines. One method is to tightlywrap a shop towel around a fuel line fitting and loosen or disconnect the fitting. Cleanliness is essential when working with fuel circuit components. Thoroughly clean the unions before disconnecting fuel lines. NOTE" On M44 engines, a Schrmder valve is integrated in the fuel rail. Compressed air pressure can be applied at the valve to force the fuel in the system back into the tank. See Fig . 11 .

0012699

Fig. 12 . Fuel linos at rear of intake manifold on M52 engine . Use BMW special tool 16 1 050 to release fittings . WARNING " Gasoline is highly flammable and its vapors are explosive. " The fuel pressure gauge must be securely connected to prevent it from coming loose under pressure . NOTE" The fuel pressure gauge should have a rango of 0 to 5 bar (0 to 75 psi) . " On 6-cylinder engine, the top left-sido engine cover will have to be removed to access the fuel rail.

Residual fuel pressure, testing

0012503

Fig. 11 . Fuel rail showing location of Schraeder valve fitting on M44 engine (arrow). NOTEB~ specifies a special gauge and special connecting

adapters to measure fuel pressure . If the special tools are not available, a length of fuel fine and a T-fitting can be installed to the inlet fuel fine and connected to a fuel gauge. On some vehicles, this is not possible without cutting finto a fuel lino . In these lnstances, it Is recommended that fuel pressure be checked at the output sido of the fuel pump. See 160 Fuel Tank and Fuel Pump .

FUEL DELIVERY TESTS

For quick restarts and to avoid vapor lock when the engine is hot, the fuel injection system is designed to retain fuel pressure after the engine has been turned off . Thís residual pressure is primarily maíntained by a check valve at the fuel pump outiet and the fuel pressure regulator. The fuel pump check valve is not serviceable as an individual part . 1 . Relieve fuel pressure and connect a pressure gauge as described earlier. WARNING Fuel will be discharged. Wrap a shop towel around the fuel lino fitting when disconnecting the fuel fine. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

2. Operate fuel pump for approximately one minuto by bypassing fuel pump relay as described earlier. Observe fuel pressure .

FUEL INJECTION 3. Observe fuel pressure gauge after 20 minutes. The pressure should not drop off more than 0 .5 bar from system pressure listed in Table c. 4. When finished testing, disconnect pressure gauge and reconnect fuel line . If the fuel system does not maintain pressure, checkvisual¡y for leaks in fuel lines or at unions . Leaks can also be due to a leaking injector or a faulty fuel pump checkvalve. Check the pump check valve by repeating the test, but before turning the fuel pump off, pinch off the retum line at the fuel rail. If the pressure is now maintained, the fault is most likely the fuel pump check valva. Tabla c. Fuel Pressure Specifications Engine

1 Fuel pressure

4-cytinder

1 3 .0 t 0 .2 bar (43 .5 t 2 .9 psi)

6-cytinder M50/S50US engine M52/S52US engine

3 .0 t 0 .2 bar (43 .5 ± 2 .9 psi) 3 .5 f 0 .2 bar (51 t 2 .9 psi)

130- 1 1

Fuel rail and injectors, checking The fuel injectors are switched on and off (opened and closed) by the ECM . The injectors are connected to a common fuel supply, callad the fuel rail . The fuel injectors are removed by first removing the complete fuel rail assembly and then unclipping the injectors from the fuel rail . CA UTION-

Use only a digital multimeter or an LED injector tester when testing injectors or wiring. Use of an analog VOM or incandescent test light may damage the engine control module.

NOTE-

" On 4-cytinder cars pry up the injector wiring duct and then pry off the cover. See Fig. 13. " On 6-cytinder cars it is necessary to remove the top engine cover(s) to access the fuel rail and injectors .

Fuel pressure regulator response to engine load, testing 1 . With fuel pressure gauge connected, reinstall fuel pump relay. Start engine and allow it to idle . NOTE-

The fuel pressure should be lower by 0.4-0.7 bar from the specifications listed in Table c. Engine vacuum acting on the fuel pressure regulator diaphragm reduces the fuel pressure.

2. With engine idling, remove vacuum hose from regulator. Pressure should increase . 3. Reconnect hose and check that pressure decreases. 4. When finished testing, disconnect pressure gauge and reconnect fuel line . Tighten hose clamp. If fuel pressure does not drop with the vacuum hose connected and no faulty are found with fuel the pressure regulator vacuum hose, the fuel pressure regulator is faulty . NOTE-

A cracked or leaktng pressure-regulator vacuum hose may cause en erratic tdle.

0013190

Fig. 13 . For electrical tests, 4-cytinder fuel injector harness duct can be accessed between intake manifold and cytinder head cover. 1 . Check that ECM signal is present at injector connector. " Back probe injector harness connector using digital voltmeter. See Fig. 14. " Operate starter or run engine and check for pulsad voltage signal . " Repeat for each injector. NOTE -

To quick-check if en injector functioning, place a screwdriver or stethoscope on the injector with the engine running. If the injector is operating, there should be en audible buzz.

FUEL DELIVERYTESTS

130- 1 2

FUEL INJECTION

Fig . 14 . Voitmeter connected across fuel injector connector with engine running . M50 engine shown . 2 . If no signal is present, check for b+ power to injectors . There should be battery voltage (+) at red/white wire of each injector connector with the ignition key on . If voltage is not present, check main relay output . Injector b+ power comes from main relay (terminal 87) .

Fig . 15 . Injector wiring harness duct being removed from M50 engine . NOTE Late-model M42 and all M44 fuel injectors are afrshrouded. See Fig. 16. When removing the fuel rail it is necessary to remove the air shroud feeder hose from the intake manifold ducting.

NOTEIf there is positive (+) battery voltage at injectors but there was no pulsed response at voltmeter, check the wire(s) from the ECM to the injectors. If no wiring faults can be found, the pulsed ground signal from the control module may be missing. Check the outputs from the ECM.

Fuel rail and injectors, replacing 1 . Disconnect negative (-) battery cable . CAUTIONPrior to disconnectiog the battery, read the battery disconnection cautions given at the tront of this manual on page viii. 2 . M42 and M50/S50US engines : Working at end of fuel rail, disconnect small vacuum hose from fuel pressure regulator. 3 . M50/S50US engines : Remove two nuts from injector duct . Carefully pry injector wiring duct off ínjectors . See Fig . 15 . 4 . On 4-cylinder cars, remove upper intake manifold to access the fuel-rail and injectors . See 113 Cylinder Head Removal and Installation .

Fig . 16 . Cutaway view of fuel injector used on M42 or M44 engine . 5 . Disconnect fuel supply line and fuel retum line from fuel rail ends . WARNING " Clamp off the fuel lines and then wrap a clean shop towei around the lines before removing them . Residual fuel pressure is present in the lines . " Fuel will be discharged. Do not disconnect any wires that could cause electrical sparks. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

FUEL DELIVERY TESTS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

FUEL INJECTION

130- 1 3

Fuel Pressure Regulator

6. Remove fuel rail mounting bolts . See Fig. 17 .

The fuel pressure regulator location on E36 models is mounted in one of two locations: Fuel Pressure Regulator Location " 4-cylinder engines 1992- January 1997 . . . . . . . . . . . . . . . . . on fuel rail January 1997- on . . . . . . . . . . . . . . . . . . . . under car " 6-cylinderengines 1992-1995 . . . . . . . . . . . . . . . . . . . . . . . . . on fuel rail 1996-on . . . . . . . . . . . . . . . . . . . . . . . . . . . undercar

Fuel pressure regulator, replacing (fuel rail mount) 0012504

Fig. 17 . Location of fuel rail mounting bolts (A) and fuel inlet and return lines (B) on M44 engine . Upper manifold has been removed. 7. Pull up on fuel rail and remove injector rail with injectors . Remove individual injectors by removing injector retaining clip and pulling injector from rail . See Fig. 18 .

WARNING Fuel will be discharged. Do not disconnect any wires that could cause electrícal sparks. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.

9. On 6-cylinder engines, remove top engine covers . Remove fuel rail mounting bolts and lift up fuel rail . 1 . Disconnect vacuum hose from fuel pressure regulator. See Fig. 19 .

Fig. 18 . Pry retaining clip from injector (1), then pull injector from rail (2). 8. Installation is reverse of removal.

" Fit new O-rings when installing injectors. For ease of installation, lightly lubricate O-rings with SAE 90 or equivalent lubricant. " Check that injector electrical connections are correctly fitted and that injectors are fully seated prior to installing fuel rail mounting bolts. " Replace wire ties .

Tightening Torque " Fuel rail to cylinder head . . . . . . . . . . 10 Nm (89 in-lb)

0012732

Fig. 19 . Fuel pressure regulator (arrow) on M42 engine . Vacuum hose shown at A. 2. Remove bolt from regulator clamp. Remove clamp. Note installed direction of regulator to fuel rail . 3. Wrap a shop rag around regulator, then remove regulator from fuel rail by pulling straight out.

FUEL DELIVERY TESTS

130- 1 4

FUEL INJECTION

NOTEBe sure to retrieve thrust washer behind fuel pressure regulator on 6-cylinder engine .

4. Installation is reverse of removal. Replace O-rings.

Fuel pressure regulator, replacing (under car mount)

BOSCH DME Ml .7 COMPONENT TESTS AND REPAIRS CA UTIONUse only a digital multimeter when testing components and wiring . Use of an analog VOM may damage the engine control module .

4-cylinder cars with M42 engines (1992 to 1995) use the Bosch DME M1 .7 fuel injection system .

WARNING Fuel will be discharged. Do not disconnect any wires that could cause electrical sparks. Do not smoke or work near heaters or other fire hazards . Keep an approved tire extinguisher handy.

Electrical tests of the main and fuel pump relays and the DME engine control module (ECM) are covered earlier in this section. Fuel pump tests are covered in 160 Fuel Tank and Fuel Pump .

On late 4- and 6-cylinder cars, the fuel pressure regulator is mounted beneath the left side of the car, under a protective cover. See Fig. 20 .

Air flow sensor, testing and replacing DME M1 .7 fuel injection uses a volume air flow type sensor with integrated intake air temperature (IAT) sensor. The sensor provides avarying voltage signal to the ECM based on the position of the air vane . As the vane door swings open the potentiometer increases the voltage signal to the ECM. The IAT sensor adapts the output signal to the ECM based on intake air temperature . 1 . Check ECM reference voltage to sensor:

0012726

Fig. 20 . Fuel pressure regulator location underneath car (arrow). Vacuum hose to regulator is shown at A. (Protective cover has been removed.) 1 . Working under car below driver's seat, remove protective cover from below fuel pressure regulator. 2. Remove vacuum hose from fuel pressure regulator. 3. Remove locking clip retaining fuel pressure regulator. 4. Wrap a shop rag around regulator, then remove regulator from 213 way valve by pulling straight out. 5. Installation is reverse of removal. Replace O-rings.

BOSCH DME Ml . 7 COMPONENT TESTS AND REPAIRS

" Peel back rubber boot from air flow sensor harness connector. " Turn ignition key on . " Check for 5 volts between terminal 1 of harness connector and ground . See Fig. 21 . " Turn ignition key off. " If voltage is not present or incorrect, check wring from ECM and check air flow sensor reference voltage output at ECM. See Table h. 2. Check air flow sensor potentiometer:

" Remove intake air boot from sensor. " Connect adigital multimeter (ohms) across terminais 1 and 2. Swing air flow sensor vane through its travel range. Resistance should change steadily without interruption . " If any faults are found, the air flow sensor is faulty and should be replaced .

3. Check IAT sensor resistance : " With harness connector disconnected at air flow sensor, check resistance across sensor terminais 4 and 5 of air flow sensor. Compare tests results to values in Table d given later. If any faults are found, the air flow sensor should be replaced .

FUEL INJECTION

130- 1 5

u0 I .[ Ia

Fig . 21 . Air flow sensor harness connector terminal identification . 4 . Replacing air flow sensor :

0011984

" Remove large band clamp attaching air boot to sensor. " Remove airfiltertop cover, then remove airflow sensor mounting nuts inside cover . " Reconnect air boot and harness connector.

Fig . 22 . M42 engine coolant temperature (ECG sensor (arrow) .

Table d. Engine Coolant Temperature Sensor or Intake Air Temperature Sensor Test Values (DME 1 .7)

Engine coolant temperature (ECT) sensor, testing and replacing The engine coolant temperature (ECT) sensor sends continuous engine coolant temperature information to the ECM . As temperature increases, sensor resistance decreases . The ECT sensor is located under number one intake runner . See Fig . 22 .

1 . Check ECM referente voltage to sensor :

" Disconnect harness connector from ECT sensor . " Turn ignition key on . " Check for 5 volts between supply voltage (brown/red) wire of harness connector and ground . " Turn ignition key off. " If voltage is not present or incorrect, check wring from ECM and check ECT sensor reference voltage output at ECM. See Table h.

2. Check ECT sensor resistance : " With harness connector disconnected, check resistance across sensor terminals . " Compare tests results to values in Table d .

Test temperatures

Resistance (k ohms) ',

14±2°F(-10t1°C)

7-11 .6

68 ± 2°F (20 t 1 °C)

2 .1 -2 .9

176 ± 2°F (80 t V C)

0 .27-0 .40

NOTEThe test values listed represent only three test points from a continuous resistance NTC sensor. Check the full linear response to increasing temperature as the engine warms up.

3. If ECT sensor fails these tests, it is faulty and should be replaced . If no faults are found, reconnect electrical harness. NOTEUse a new copper sealing washer when installing sensor. Reptace any lost coolant. WARNING Do not replace the ECT sensor unless the engine is cold. Hot coolant can scald.

Tightening Torque " ECT sensor to cylinder head . . . . . . . 13 Nm (10 ft-Ib) BOSCH DME M1 .7 COMPONENT TESTS AND REPAIRS

130- 1 6

FUEL INJECTION

Throttie position sensor (TPS), testing and replacing

Idie speed control valve, testing and replacing

The throttie position sensor (TPS) is mounted on the side of the throttie housing and is directly connected to the throttie valve shaft. The ECM sends a voltage signal to the potentiometer-type sensor and monitors the voltage that comes back .

¡die speed is maintained by the ECM via the ¡die speed control valve. See Fig. 24 . ¡die speed is adaptive through the ECM and no ¡die speed adjustments can be made . Before testing the valve, confirm that the throttie position sensor (TPS) is working correctly.

Check TPS function by disconnecting the harness connector and checking reference voltage and sensor resistance . See Table e and Fig. 23. If voltage is not present, check the output voltage signal from the ECM and check the wiring between the sensor and the ECM . If the sensor resistance is incorrect, replace the throttie position sensor .

Fig. 24 . ¡die speed control valve (arrow) on M42 engine .

0013235

Fig. 23. Throttie position sensor terminal identification on M42 engine . NOTE The throttie position sensor is not adjustable. If test results are íncorrect, the sensor should be replaced .

Table e. Throttle Position Sensor Tests (DME 1 .7) Test conditions

1 Terminais

Harness connec- ( 1 and ground in tor disconnected, harness connector ignition on Harness connector disconnected, ignition off Connector disconnected, ignition off. Throttle rotated from ¡die to fui] position

1 Test value

15 VDC (approx.)

I 1 and 3 at sensor ( 4 k ohms (approx.) terminais

1 and 2 at sensor terminais

Continuously variable from 1-4 k ohms (approx.) with out interruption

BOSCH DME Ml .7 COMPONENT TESTS AND REPAIRS

0013226

NOTE " The tests given below are electrical checks only. They do not check the mechanical operation of the valve or if the valve is sticking or worn . If the valve is suspect, substituting a known good valve is the best way to check for a mechanical fault.

1 . Check battery (+) voltage to valve:

" Disconnect harness connector from valve. " Check for batteryvoltage at terminal 2 (red/white wire). " If voltage is not present check wiring between valve and main relay (terminal 87).

2. Check that ECM signal is reaching valve:

" With engine running, check that ¡die speed control valve is audibly buzzing . " If valve is not working, disconnect wiring harness connector. " Connect 12V probe light across connector terminais . " Turn ignition key on ; probe should light. lf probe does noflight, check the wiring from the ECM (pin 29) to the valve. See Table h. lf probe does light but ¡die quality is poor, the valve is most likely sticking and or worn and should be replaced .

FUEL INJECTION

130- 1 7

BOSCH DME MM AND M33.1

COMPONENT TESTS AND REPAIRS Consult Table a for engine application information for the Bosch DME 3.1 and 3.3 .1 systems. The DME 3.1 and DME 3.3 .1 systems are similar in operation, with knock control and VANOS operation being the key differences . DME 3.1 engines are not equipped with VANOS or knock detectors, while the DM E 3.3 .1 system is . CA UTION-

Use onty a digital multimeter when testing wiring. Use of an analog VOM may damage the engine control module.

Electrical tests of the main and fuel pump relays and the DME engine control module (ECM) are covered earlier in this section . Fuel pump tests are covered in 160 Fuel Tank and Fuel Pump.

Mass Air Flow Sensor

Fig. 25. Mass air flow sensor. Hot wire sensor used on cars with DME 3.1 (1992 6-cylinder models). CAUTION-

Use only a digital multimeter when checking the mass air flow sensor. An analog meter can damage the air flow sensor.

There are two types of mass air flow sensors used on the cars covered by this section. Testing procedures vary depending on type installed. The airflow sensor is not adjustable and must only be tested with a digital multimeter .

1 . Disconnect air flow sensor from air cleaner only. Leave it connected to duct leading to intake manifold and leave wiring harness connected.

Mass Air Flow Sensor Variants " 1992 M50 engine DME M3 .1 . . . . . . . . . mass air flow sensor-hot wire " 1993-1995 M50 and S50US DME M33 .1) . . . . . . . . mass air flow sensor-hot film

3. Rev engine to at least 2,500 rpm, then shut it off. Look through meter at hot wire . After approximately four seconds wire should glow brightly for about one second .

Mass air flow sensor (hot wire), testing and replacing When the engine is running, a current is used to heat a thin wire in the center of the sensor . See Fig. 25 . The current in the wire is regulated to maintain a temperature of 100°C more than the air passing over it . The current used to heat the wire is electronically conneced into a voltage measurement corresponding to the mass of intake a¡ r. To keep the wire clean, it is heated to a temperature of about 1,000°C (1,830°F) for one second . This "burn-off" cycle takes place automatically, four seconds after the engine is tumed off. lf the hotwire breaks or if there is no output from the airflow sensor, the ECM automatically switches to a "limp-home" mode and tucos on the Check Engine light. The engine can usually be started and driven . The airflow sensor has no internal moving parts and cannot be serviced .

2. Start engine and run it to normal operating temperature .

NOTE -

If the wire glows as specified, then the airflow meter and ECM are probably operating correctly. lf the wire does not glow, continue testing.

4. lf the wire does not glow, remove air flow sensor and look through it to see if wire is broken . lf wire is broken, meter will have to be replaced . 5. Reinstall air flow sensor and harness connector. Peel back rubber boot from harness connector. Working from rear of connector, connect digital voltmeter across terminals 1 and 4. See Fig. 26 . 6. Start and rev engine to at least 2,500 rpm, then shut it off. After about 4 seconds, voltage should rise to about 4 volts for about one second . lf voltage is present, but wire does not glow, air flow sensor is faulty and should be replaced . 7. lf voltage is not present in step 6, turn ignition key on and check for voltage and ground at sensor. There should be ground at pin 4. There should be positive (+) battery voltage at pin 2.

BOSCH DME M3 .1 AND M32.1 COMPONENT TESTS AND REPAIRS

130-18

FUEL INJECTION 1 . Disconnect harness connector from air flow sensor. 2. Turn ignition on and check for voltage and ground at connector . There should be ground at pin 1 . There should be positive (+) battery voltage at pin 3. If any faults are found, check wiring to and from ECM. Make ECM pinout test . See Table j. NOTE-

Positive (+) battery voltage to air flow sensor comes from DME main relay when the ignition is switch on or engine running.

Engine coolant temperature (ECT) sensor, testing and replacing Fig. 26. Mass air flow sensor terminal identifcation on cars with DME M3 .1 fuel injection. 8 . With ignition off, disconnect harness connector from air flow sensor. Using a digital multimeter, check resistance at terminals listed .

The engine coolant temperature (ECT) sensor sends continuous engine coolant temperature information to the ECM. As temperature increases sensor resistance decreases. ECT Sensor Location " M50/S50US engine . . . . . . . . . . . . left side of cylinder head under intake manifold

Air Flow Sensor Test Values (DME M3 .1) " Terminals 5 and 6. . . . . . . . . . . . . . . . . . . . . 3-4 ohms If any faults are found, check wiring lo and from the ECM. Make ECM pinout test as listed in See Table i. Main power to air flow sensor comes from DME main relay.

Mass air flow sensor (hot film), testing and replacing On cars with DME M3 .3 .1 a hot film mass air flow sensor is used . When the engine is running, a current is used lo heat a thin film in the center of the sensor. This current is electronically converted into a voltage measurement corresponding to the mass of intake air. MOTE-

A burn-off cycle is not used on hot film sensors.

0012704

Fig. 27 . Engine coolant temperature (ECT) sensor (A) is located beneath top engine cover (B) and crankcase vent hose (C). M52 engine shown. M50 is similar. 1 . Check ECM reference voltage to sensor :

" Disconnect harness connector from ECT sensor . " Turn ignition key on . " Check for 5 volts between supply voltage wire (brown/red) wire of harness connector and ground . " Turn ignition key off. " If voltage is' not present or incorrect, check wiring from ECM and check reference voltage output at ECM (pin 78). See Table i (DM E 3.1) or Table j (DME 3.3 .1)

If the hot film breaks or if there is no output from the air flow sensor, the ECM automatically switches to a "limp-home" mode and tucos on the Check Engine light . The engine can usually be started and driven . The air flow sensor has no internal moving parts and cannot be senriced or adjusted . CA UTION-

Use only a digital multimeter when checking the mass air flow sensor. An analog meter can damage the air flow sensor.

2 . Check ECT sensor resistance :

BOSCH DME M3. 1 AND M32 .1 COMPONENT TESTS AND REPAIRS

" With harness connector disconnected, check resistance across sensor terminals . " Compare tests results to values in Table f.

FUEL INJECTION

130-19

Table f. Engine Coolant Temperature Sensor or Intake Air Temperature Sensor Test Values (DME 3.113 .3 .1) Test temperatures

Resistance (k ohms)

14 ± 2°F (-10 ± 1'C)

7-11 .6

68 ± 2°F (20 ± 1'C)

2 .1 -2 .9

176 1 2°F (80 t V C)

0 .27-0 .40

NOTE The test values listed represent only three test points from a continuous resistance NTC sensor. Check the full linear response to increasing temperatures as the engine warms up.

3. If ECT sensor fails these tests, it is faulty and should be replaced . If no faults are found, reconnect electrical harness. WARNING Do not replace the ECT sensor unless the engine is cold. Hot coolant can scald.

Fig . 28. Intake air temperature sensor location on M50/S50US engine (arrow) .

If voltage is not present or incorrect, check wiring from ECM and check reference voltage signal at ECM (pin 77). See Table i or Table j.

NOTE" Use a new copper sealing washer when installing sensor. Replace any lost coolant.

2. Check IAT sensor resistance :

Tightening Torque " Engine coolant temperature sensor to cylinder head . . . . . . . . . . . . . . . . . 13 Nm (10 ft-lb)

" With harness connector disconnected, check resistance across sensor terminals. Compare tests resuits to values in Table f given earlier. " If IAT sensor fafs this test it is faulty and should be replaced . 3. If no faults are found, reconnect electrical harness.

Throttle position sensor (TPS), testing and replacing

Intake air temperature (IAT) sensor, testing and replacing The intake air temperature (IAT) sensor signal is used as a correction factor forfuel injection and ignition timing . This sensor is mounted in the intake manifold behind the throttle position switch . See Fig. 28 . 1 . Check that ECM reference voltage is reaching IAT sensor: " Disconnect IAT sensor harness connector. " Turn ignition key on . " Check for 5 volts between supply voltage wire of harness connector and ground . " Turn ignition key off.

The throttle position sensor (TPS) is mounted on the side of the throttle housing and is directly connected to the throttle valve shaft. The ECM sends a voltage signal to the potentiometer-type sensor and monitors the voltage that comes back . Check TPS function by disconnecting the harness connector and testing continuity across the terminals while changing the throttle position . Resistance test values are listed below. If the resuits are incorrect, replace the throttle position sensor . See Fig . 29 . NOTEThe throttle position sensor is not adjustable. If test results are incorrect, the sensor should be replaced.

IAT Sensor Supply Voltage " M50/S50US engines . . . . . . . . . grey wire and ground

BOSCH DME M3. 1 AND M32.1 COMPONENT TESTS AND REPAIRS

130-20

FUEL INJECTION NOTE-

" The tests given below are electrical checks only. They do not check the mechanical operation of the valve. If the valve is suspected of causingpoor idie, substituting a known good valve is the best way to check fora mechanical fault. 1 . With engine running, check that ¡die speed control valve is buzzing. 2. Turn on A/C or shift car finto drive. ¡die should remain steady or increase slightly. 3. If valve is not buzzing, or if ¡die decreases in step 2, stop engine and disconnect harness connector from valve. Check resistance of valve across its terminals. See Fig. 30 . Test values are listed below.

NOTE -

If you suspect an intermittent fault, lightly tap the valve

while testing resistance .

Fig . 29. Throttle position sensor terminal identification on M50 engine.

Table g. Throttle Position Sensor Tests (DME 3.113.3.1) Test conditions

I Terminals

Harness connector disconnected, ignition on

13 and ground in harness connector

I Test value

15 VDC (approx .)

Harness connector disconnected, ignition off

1 and 3 at sen- 14 k ohms (approx .) sor terminals

Throttle plate rotated from ¡die to full throttle position

1 and 2 at sensor terminals

Variable from 1 - 4 k ohms (approx .) without interruption

NOTE-

On cars with traction control, do notconfuse the throttle position sensor on the main throttle body with the throttle position switch on the secondary throttle body, where applicable .

¡die speed control valve, testing

11250

Fig. 30 . ¡die speed control valve terminal identification . ¡die Speed Control Valve Coil Resistance Values " M50/S50US engine

Terminals 1 and 2 . . . . . . . . . . . . . . . . . . . 20 t 5 ohms Terminals 2 and 3 . . . . . . . . . . . . . . . . . . . 20 t 5 ohms Terminals 1 and 3 . . . . . : . . . . . . . . . . . . .40 t 5 ohms

4. With valve harness connector disconnected, check for battery voltage at red/white wire in connector with ignition tumed on .

¡die speed is maintained by the ECM through the ¡die speed control valve. The ¡die control function compensates for engine load and engine operating conditions . ¡die speed is adaptive through the ECM and no ¡die speed adjustments can be made .

" If there is no voltage, check wiring between connector and main relay terminal 87 . See Electrical Wiring Diagrams .

Before testing the valve, confirm that the throttle position sensor is working correctly.

The idle speed control valve receives positive (+) battery voltage from the main relay.

NOTE-

5. If voltage is presentas described above, check wiring between ECM and valve. If no wiring faults are found, check ECM signal to valve.

BOSCH DME M3. 1 AND M3.3.1 COMPONENT TESTS AND REPAIRS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

FUEL INJECTION NOTE-

" The Ole speed control valve signal can be checked using a duty cycle meter (or dwell meter). Connect the meter to the valve following the manufacturer's instructions. Turn on the WC or create a larga air leak and check that the meter reading reacts while the idle speed remains steady. " There are some additional inputs to the control module that affect idle speed (Le. throttle position, AIC-on signals, and AIT Drive position). Check these signals 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 accomplished by first removing the intake manifold .

NOTE-

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

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

130-21

NOTE-

The intake manifold is held in place with 7 nuts from above and 2 support bracket bolts from undemeath. On DME 3.1 cars, carefully disconnect the idle air hose from the intake manifold when lifting the manifold off. For more information, sea 113 Cylinder Head Removal and Installation .

5. Disconnect al¡ necessary hoses and remove idle speed control valve. 6. Installation is reverse of Removal. Use new gaskets when installing intake manifold .

NOTE-

Poor driveability may be noticed after installing a replacement idle speed control valve. After about 10 minutes of driving, the system will adapt the base setting of the valva and the idle speed should retum to normal.

Tightening Torque " Intake manifold 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 warning light will also come on if an emissions-relatad fault is detected . The most efficient way to diagnose the Bosch OBD II system 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 diagnostics is not covered here . Fi 9 . 31 . Remove to P en gine covers b Prying out caPs and removing

nuts (A)

Note 14 L-tey at cover edge (arrows) .

2. Remove two hold down nuts from fuel injector wiring duct . Pry back injector connector retainers and lift off wiring duct . 3. Disconnect intake air boot from throttle housing. Where applicable disconnect accelerator cable and cruise control cable from their brackets . 4. Unbolt intake manifold and move it out of way enough to access idle speed control valva.

NOTE-

" The OBD 11 fault memory (including an iiluminated

Check Engine light) can only be reset using the special scan tool. Removing the connector from the ECM or disconnecting the battery will not arase the fault memory.

" The 16-pin OBD Il diagnostic connector is located on the lower left dash panel. Refer to Fig. 1.

" BMW special scan tool or a `generic"OBD II scan tool must be used to access DTCs. " Tabla k lists engine control module (ECM) pinouts for the DME M5.2 system

BOSCH DME M5.2 COMPONENT REPLACEMENT

130-22

FUEL INJECTION

Mass air flow sensor, replacing 1 . Disconnect harness connector and intake air boot from air flow sensor. See Fig. 32 .

U1111 bis4a

Fig. 33 . M44 engine coolant temperature (ECT) sensor located above oil filter (arrow). Fig. 32 . To detach airflow sensor, disconnect harness connector (A); unclip retainíng clipsto aír filter housing (B); and remove large hose clamp at air intake bellows (C). M44 engine with traction control shown. 2. Detach two large clips at air filter housing and work air flow sensor out of rubber seal in filter housing. 3. Installation is reverse of removal. " For ease of installation, lubricate large rubber seal in air filter housing with silicone lubricant or equivalent. " No adjustment to air flow sensor is possible. " Carefully check that all hoses and seals are seated properly.

Engine coolant temperature (ECT) sensor, replacing The engine coolant temperature (ECT) sensor is a dual temperature sensor . One circuít provides coolant temperature information to the ECM while the other circuít provides coolant temperature information to the instrument cluster. WARNING Do not replace the ECT sensor unless the engine is cold. Hot coolant can scald.

1 . Disconnect harness connector from ECT sensor. See Fig . 33 . 2. Unscrew temperature sensor from cylinder head and remove BOSCH DME M5.2 COMPONENTREPLACEMENT

3. Installation is reverse of removal.

" Use a new copper sealing washer when installing sensor. " Replace any lost coolant.

Tightening Torque " Engine coolant temperature to cylinder head . . . . . . . . . . . . . . . . . 13 Nm (10 ft-Ib)

Intake air temperature (IAT) sensor, replacing The intake air temperature (IAT) sensor on cars with M44 engine is mounted in the top section of the intake air filter housing . See Fig. 34 . 1 . Remove electrical harness connector from IAT sensor . 2. Unclip temperature sensor and remove from air filter housing. 3. Installation is reverse of removal .

Throttle position sensor (TPS), replacing The throttle position sensor is located on the side of the throttle housing. See Fig. 35 . 1 . Unplug harness connector from sensor.

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 0rings and seals. NOTE Poor driveability may be notíced after installing a replacement ¡dio control valve. After about 10 minutes of driving, the idie speed should retum to normal.

SIEMENS MS 41 .1 COMPONENT REPLACEMENT 001ía4

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

On-Board Diagnostics II (OBD II) is incorporated into the Siemens 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 of faults . 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 capable of storing hundreds of faults, making diagnostics with a scan tool the only viable method . Therefore, system diagnostics is not covered here .

0012725

Fig. 35 . M44 engine: Throttle housing showing (A) throttle position sensor (fPS) and (B) ¡die speed control valve. 2. Remove two mounting screws holding sensor to throttle housing. 3. Installation is reverse of removal. No adjustment is nec essary.

NOTE " The OBD 11 fault memory (including an illuminated Check Engine light) can only be reset using the special 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 . special scan tool or a "generic" OBD 11 scan tool must be used to access DTCs.

" BMW

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

¡die speed control valve, replacing The ¡die speed valve on the M44 engine is located on the side of the throttle body . See Fig. 35 . 1 . Disconnect harness connector from ¡die valve.

SIEMENS MS 41 . 1 COMPONENT REPLACEMENT

130-24

FUEL INJECTION ECM RELAY CONTROL

TERMINAL 15 MEMORY POWER

FUEL PUMP RELAY CONTROL

AUX GROUND í1

MAIN GROUND RELAY ..

AC COMPRESSOR RELAY CONTROL

CRANKSHAFT POSITION qtcMSENSOR

~® oayi

SECONDARY AIR INJECTION AIR PUMP RELAY CONTROL -

CAMSHAFT POSITION SENSOR

~ :UhI~IIUH~W~`bY~7~d~t~II7 . ,

.. 1111111

~ilf PRE CAT

THROTTLE POSITION ENGINE COOLANT TEMP

POST CAT mnXYGEN SENSOR HEATING

ys ~ U

FUEL ((INJECTOR CONTROL

MS 41 .1 IGNITION COILS CONTROL PURGE CONTROL VALVE //

PURGE ' CANISTER SHUT-OFF VALVE

FUEL TANK PRESSURE SENSOR S-EML S-MSR S-ASC

1 ASC

LOW FUEL LEVEL

THROTTLE POTENTIOMETER POWER

ASC

Jo'0

o_A

VEHICLE SPEED

E36 IHKA

A/C SWITCH ON (AC)

COMPRESSOR "ON" SIGNAL (KO)

r71a .

INDIVIDUAL SERIAL NUMBER

. al; . i

" a fn7111, /

Fig. 36. Siemens MS 41 .1 OBD II engine management system used on M52 engine . Bosch M5 .2 system used on M44 engine is similar.

SIEMENS MS 41 . 1 COMPONENT REPLACEMENT

FUEL INJECTION

130-25

Mass air flow sensor, replacing 1 . Disconnect harness connector and intake air boots from air flow sensor. See Fig. 37 .

0012704b

Fig. 38. M52 engine : Engine coolant temperature (ECT) sensor (A) is located beneath top engine cover (8) and crankcase vent hose (C).

Intake air temperature (IAT) sensor, replacing The intake air temperature (IAT) sensor for the M52/S52US engine is mounted on the bottom of the intake manifold . See Fig. 39 . Fig. 37. Mass air flow sensor (arrow) on M52 engine .

0012703

2. Installation is reverse of removal. " No adjustment to aír flow sensor is possible . " Check intake hoses for cracks and vacuum leaks.

Engine coolant temperature (ECT) sensor, replacing The ECT sensor is a dual temperature sensor. One circuit provides coolant temperature information to the ECM while the other circuit provides coolant temperature information to the instrument cluster. 1 . Remove left-side top engine cover. 2. Unclip crankcase venting hose from cylinder head cover. See Fig. 38 . 3. Under intake manifold, disconnect harness connector from sensor. 4. Remove sensor. 5. Installation is reverse of removal.

" Use a new copper sealing washer when installing new sensor. " Replace any lost coolant .

Tightening Torque " Engine coolant temperature to cylinder head . . . . . . . . . . . . . . . . . 13 Nm (10 ft-Ib)

Fig. 39 . M52/S52U S engine: Intake airtemperature sensor location in bottom of intake manifold (arrow). Throttle housing shown re moved. 1 . Disconnect intake air boot from throttle housing. Unbolt throttle housing and ¡ay aside. (It is not necessary to disconnect throttle cable or electrical harness connectors from throttle housing.) 2. Remove electrical harness connector from IAT sensor. 3. Unclip temperature sensor and remove from intake manifold . 4. Installation is reverse of removal. Use a new gasket at the throttle housing. SIEMENS MS 41 .1 COMPONENT REPLACEMENT

130-26

FUEL INJECTION

Throttle position sensor (TPS), replacing

Vacuum seal

The throttie position sensor is located on the side of the throttie housing. See Fig . 40 .

Mounting bracket

Electrical connector

0013185

Fig. 41 . M52 engine : ¡die speed control valve (located under intake manifold) . Fig. 40 . M52 engine: Throttle position sensor (arrow).

0012700b

1 . Unplug harness connector from sensor . NOTE On cars with traction control, do not confuse the throttie position sensor on the main throttie body wíth the throttie position switch on the secondary throttie body, where applicable.

2. Remove two mounting screws holding sensor to throttie housing. 3. Installation is reverse of removal .

¡die speed control valve, replacing The ¡die speed control valve is mounted on the underside of the intake manifold adjacent to the dipstick tube bracket. Accessing the valve is best accomplished by first removing the throttie housing. 1 . Disconnect intake air boot from throttie housing. Unbolt throttie body and ¡ay aside. (Do not disconnect throttie cable or electrical harness connectors to throttie body.) 2. Unbolt dipstick tube bracket from intake manifold . 3. Workíng under intake manifold, disconnect electrical harness connector from ¡die speed control valve. 4. Remove two bolts retaining ¡die speed control valve to underside of intake manifold . Remove valve from intake manifold . Remove hose clamp and disconnect hose .

ECM PIN ASSIGNMENTS

5. Installation ís reverse of removal. Use new gaskets when installing . NOTE Poor driveabilíty may be noticed atter installing a replacement idle speed control valve. After about 10 minutes of dríving the idle speed should return to normal.

ECM PIN ASSIGNMENTS Engine control module (ECM), accessing

1 . Disconnect negative (-) battery cable. Wait approximately one minute. CAUTIONPrior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page vüi.

2. Remove engine control module (ECM) compartment cover from right side of engine compartment rear bulkhead . Cover is retained with four captíve screws. See Fig. 42 . 3. Disconnect control module harness connector by releasing fastener and pivoting connector up and off ECM. 4. Remove ECM from retaining brackets and pull ECM from its holder. 5. Installation is reverse of removal.

FUEL INJECTION

130-27

Generally, absence of voltage or continuity means there is a wiring or connector problem . Test results with incorrect values do not necessarily mean that a component is faulty : Check for loose, broken or corroded connections and wiring before replacing components . If the results are still incorrect, test the component itself . For engine management system electrical schematics, see Electrical Wiring Diagrams . CAUTIONAlways wait at least 40 seconds after tuniing off the ignition before removing the connector from the engine control module (ECM). If the connector is removed before this time, residual power in the system relay may damage the ECM. " Always connect or disconnect the control module connector and meter probes with the ignition off.

0013ZIM

Fig . 42 . Engine control module (ECM) located in compartment in right-rear of engine compartment (arrow) . NOTEReplacement ECMs must be coded with application information (Le. engine code, transmission type, etc.) prior to installation. Consult an authorized BMW dealer before replacing the ECM. ECM pin assignments are given in Tables h through Table I . This information can be helpful when diagnosing faults to or from the ECM . If al¡ inputs and wiring are OK but operational problems still exist, the ECM itself may be faulty .

2L4

LJ 22 ©©®®17

When making checks at the ECM itself, a breakout box should be used to allow tests to be made with the connector attached to the ECM . This also prevents damage to the small termínals in the connector . As an alternative, theharness connector housing can be separated so that electrical checks can be made from the back of the connector. ECM pin numbering is shown in Fig . 43 . NOTE On cars with traction control, do not confuse the throttle position sensor on the main throttle body with the throttle position switch on the secondary throttle body.

©©®©©~©©®©~~rui~~ru

®®®®®®®®®®®®®®®IZA®®®®®®®®®®®®®®®®® 1 >I-

0013211

Fig . 43 . ECM pin numbers as seen from back of ECM connector.

ECM PIN ASSIGNMENTS

130- 28

FUEL INJECTION Table h. ECM Pin Assignment-Bosch DME M1 .7

Signal

Componenttfunction

Signal

Fuel pump relaycontrol

Fuel pump relay, terminal 85

Cyl. 2 and cyl . 4 fuel injection valve control

Cyl. 2 and cyl. 4 fuel injection valves

Ground, fuel injection valve output stages

Ground point

"Check engine" indicator control

Instrument cluster

Output

Not used

Output

Not used

Ground

Not used

Output

Not used

Output

DKV potentiometer signal

Transmission control module (EGS)

Input

Throttle position sensor

Throttle position Signal

Not used

Input

Volume air flow sensor

Input

Cyl . 1-2 knock sensor

Cyl. 1-2 knock sensor

Input

Camshaft position sensor (cylinder identification)

Output

ti measurement signal (fuel consumption)

Instrument cluster

Output

Intake air resonance changeover valve (DISA)

Intake air resonance changeover valve

Volume air flow sensor (signal ground)

Not used

Output

Cyl. 3 ignition coil control

Cyl. 3 ignition coil

Output

Cyl. 1 ignition coil control

Cyl. 1 ignition coil

Input

Battery voltage

B +junction point

Output

Engine control module relay control

Engine control module relay, terminal 85

Ground

Ground for electronics and shielding of sensors

Ground point

Output

Idle speed control valve control

Idle speed control valve

Not used

Output

Cyl. 1 and cyl . 3 fuel injection valve control

Cyl . 1 and cyl . 3 fuel injection valves

Not used

Ground

Ground, output stages (except for ignition and fuel injection valves)

Ground point

Not used

Output

Evaporative emission valve control

Evaporative emission valve

Output

Oxygen sensor heater control

Oxygen sensor relay, terminal 85

Not used

I Not used

I Input

, Volume Air Flow sensor

Ground

Ground for sensors

1 Input

1 Camshaft position sensor (cylinder identification) 1 Camshaft position sensor (cylinder identification)

41 42

1 Input

1 Cyl. 3-4 knock sensor

Volume air flow sensor (voltage varies with engine load)

1 Cyl . 3-4 knock sensor

Engine coolant temperature sensor, cyl. 1-2 knock sensor, cyl. 3-4 knock sensor, and throttle position sensor

ECM PIN ASSIGNMENTS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

FUEL INJECTION

130- 29

Table h. ECM Pin Assignment--Bosch DME M1 .7 Pin

1 Signal

Notused

Output

Notused

1 Component/function

1 Signal

A/C compressor cut-out

Compressor control relay, terminal 85

Output

Cyl. 4 ignition coil control

Cyl . 4 ignition coil

Output

Cyl. 2 ignition coil control

Cyl . 2 ignition coil

Not used

Input

Battery voltage from engine control module

Engine control module relay, terminal 87a

Ground

Ground, ignition

Ground point

Input

Ignition switch, terminal 15

Notused

Not used

Output

Throttle position sensor and volume air flow sensor

Reference voltage (5 VDC)

Input

Programming voltage

Data link connector

Notused

Input

Ignition timing intervention

Transmission control module (EGS)

Input

Drive range P/N

Automatic transmission range switch

Notused

Input

Crankshaft position RPM sensor

Input

Crankshaft position RPM sensor

Notused

Input

Oxygen sensor signal

Heated oxygen sensor

Ground

Oxygen sensor signal ground

Heated oxygen sensor

Notused

Input

Vehicle speed signal

Instrument cluster

Output

Engine speed signal

Instrument cluster

Not used

Input

Volume air flow sensor

Input

Intake airtemperature sensor (IAT)

Intake air temperature sensor (IAT)

Input

Engine coolant temperature

Engine coolant temperature sensor

Notused

Not used

Input

Drive-away protection signal (code)

On-board computer

Not used

Notused

Not used

Input

A/C pressure

Pressure switch

Input

A/C switch

Integrated climate regulation control module

Output

RxD diagnosis data line

Data link connector

Output-Input

TxD diagnosis data line

l Data link connector

ECM PIN ASSIGNMENTS

130- 30

FUEL INJECTION

Table 1. ECM Pin Assignment-Bosch DME M3 .1 Pin

Signal

Component/function

Signal

output

Fuel pump relay control

Fuel pump relay switches with engine running or cranking (crankshaft position Signal must be present for relay switchover)

1 output

1 Idle speed control valve

1 Pulsad ground- close signal (see also pin 29) Pulsed ground (injection pulse width in ms) with engine running

output

Fuel injector control, cyl. 1

output

Fuel injector control, cyl . 3

Pulsed ground (injection pulse width in ms) with engine running

output

Fuel injector control, cyl. 2

Pulsed ground (injection pulse width in ms) with engine running

ground

Ground

Ground for fuel injector output stages

vacant

output

Check Engine

Check éngine lamp control ground

vacant

output

Throttle valve position

Load signal to transmission control module

input

Throttle position sensor

Voltage varies with throttle position

output

Mass air flow sensor

Air flow sensor hot wire burn off (voltage for 0.5 seconds after shutdown)

ground

Mass air flow sensor

Ground for air flow sensor

vacant

input

Cylinder identification sensor

A/C voltage pulse per camshaft revolution (between pin 16 and 44)

output

Fuel consumption (ti)

Fuel consumption output (KVA Signal) to instrument cluster

vacant

output

Ignition control (terminal 1), cyl. no. 2

Primary Signal, ignition coil cyl. no. 2

output

Ignition control (terminal 1), cyl. no. 3

Primary signal, ignition coil cyl. no. 3

output

Ignition control (terminal 1), cyl. no. 1

Primary signal, ignitioh coil cyl. no. 1

input

Power supply (terminal 30)

Battery voltage (B+) at al¡ times (terminal 30)

output

Main relay control

Main relay activation (to relay terminal 85)

ground

Ground

Ground for ECM and sensor shielding

output

Idle speed control valve

Pulsed ground- open signal (see also pin 2)

vacant

output

Fuel injector, cyl. no. 5

Pulsed ground (injection pulse width in ms), cyl. no. 5

output

Fuel injector, cyl. no. 6

Pulsed ground (injection pulse width in ms), cyl. no. 6

output

Fuel injector, cyl. no. 4

Pulsed ground (injection pulse width in ms), cyl. no. 4

ground

Ground

Ground for output stages

vacant

output

Evaporative purge valve control

Pulsed ground with engine at normal temperature and varying engine load

output

Oxygen sensor heater relay control

Oxygen sensor heater relay activation (ground at terminal 85)

vacant

input

Mass air flow sensor

Voltage (+)

vacant

ground

Ground

Ground fortemperatura sensors (ECT sensor, IAT sensor, TP sensor)

input

Cylinder identification sensor

A/C voltage pulse per camshaft revolution (between pin 16 and 44)

ECM PINASSIGNMENTS

FUEL INJECTION

130-3 1

Table i. ECM Pin Assignment-Bosch DME M3.1 Pin

Signal

Component/function

vacant

ignal

output

A/C compressor control

A/C compressor disabled via compressor control relay

vacant

output

Ignition control (terminal 1), cyl . no . 4

Primary signal, ignition coil cyl. no. 4

output

Ignition control (terminal 1), cyl. no. 6

Primary signal, ignition coil cyl. no. 6

output

Ignition control (terminal 1), cyl. no. 5

vacant

Primary signal, ignition coil cyl. no. 5 -

input

Power supply

Battery voltage (+) from main relay terminal 87

ground

Ground

Ground for ignition control

input

Power supply (terminal 15)

Battery voltage (+) with key on or engine running

vacant

output

Throttle position sensor

Throttle position sensor supply voltage (5 VDC)

input

Data link connector

Programming voltage

vacant

input

Ignition timing intervention

from A/T control module (only active during gearshift)

input

Automatic transmission (A/T) range switch

Transmission park or neutral signal

vacant

input

Engine speed/crankshaft position sensor

Crankshaft position/rpm (voltage (VAC) between pins 67 and 68)

input

Engine speed/crankshaft position sensor

Crankshaft position/rpm (voltage (VAC) between pins 67 and 68)

vacant

input

Oxygen sensor

Oxygen sensor signal (0-1 VDC fluctuating with engine running)

ground

Oxygen sensor

Oxygen sensor signal ground

vacant

input

Road speed

Road speed signal from instrument cluster

output

Engine speed (TD)

Engine speed (TD) signal to instrument cluster

vacant

input

Intake air temperature (IAT) sensor

Intake air temperature (0-5 V, temperature dependent)

input

Engine coolant temperature (ECT) sensor

Engine coolant temperature (0-5 V, temperature dependent)

vacant

input

On-board computer

Drive-away protection enable

vacant

input

A/C pressure switch

From Integrated climate control module via A/C pressure switch

input

A/C compressor on

From Integrated climate control module

input

Diagnostic connector (RxD)

Diagnostic RxD (receive) signal to pin 15 in Data link connector

input/output

Diagnostic connector (TxD)

Diagnostic TxD (transmit) signal to pin 20 in Data link connector

ECM PIN ASSIGNMENTS

130- 32

FUEL INJECTION Table j. ECM Pin Assignment-Bosch DME M3.3.1

1 Signal

1 Component/function

1 Signal

output

Fuel pump relay control

Fuel pump relay switches with engine running or cranking (crankshaft position signal must be present for relay switchover)

output

Idle speed control valve

Pulsed ground-close signal (see also pin 29)

output

Fuel ínjector control, cyl. 5

Pulsed ground (injection pulse width in ms) cyl. 5

output

Fuel injector control, cyl. 6

Pulsed ground (injection pulse width in ms) cyl. 6

output

Fuel injector control, cyl. 4

Pulsed ground (injection pulse width in ms) cyl. 4

ground

Ground

Ground for fuel injector output stage

output

Camshaft actuator (VANOS solenoid) control

Camshaft actuator (VANOS solenoid)

output

Check Engine

Instrument cluster, Check Engine lamp

vacant

output

Throttle position

Throttle angle signal to A/T control module

vacant

input

Oxygen sensor

Oxygen sensor signal (0-1 VDC fluctuating with engine running)

input

Mass air flow sensor

ground

Ground

input

Crankshaft position/rpm sensor

Voltage pulse (VAC) between pin 16 and 43 (crank position/rpm sensor)

input

Camshaft position sensor

Hall effect camshaft sensor

vacant

output

Ignition coil control, cyl. 4

Ignition coil 4

output

Ignition coil control, cyl. 6

Ignition coil 6

output

Ignition coil control, cyl. 5

Ignition coil 5

input

Power supply (terminal 30)

Battery voltage (B+) at all times

input

Main relay control

Main relay activation (terminal 85)

ground

Ground

Ground for ECM and sensor shielding

output

Idle speed control valve

Pulsed ground-open signal (see also pin 2)

vacant

output

Fuel injector control, cyl. 3

Injection pulse wicith in ms-cyl . 3

output

Fuel injector control, cyl. 2

Injection pulse wicith in ms-cyl . 2

output

Fuel injector control, cyl . 1

Injection pulse width in ms-cyl . 1

ground

Ground

Ground for remaining output stages

vacant

output

Evaporative purge valve control

vacant

output

Oxygen sensor heater relay control

Oxygen sensor heater relay switchover (terminal 85)

vacant

ground

Oxygen sensor

Oxygen sensor signal ground

input

Mass air flow sensor

Mass air flow voltage signal

input

Vehicle speed

Vehicle speed signal from instrument cluster

input

Crankshaft position/rpm sensor

Voltage pulse (VAC) between pin16 and 43

ground

Ground

Ground for intake air temp . sensor, engine coolant temp . sensor, throttle position sensor

ECM PIN ASSIGNMENTS

FUEL INJECTION

130-33

Table j. ECM Pin Assignment-Bosch DME M3 .3 .1 Pin

~ Signal

1 Componentffunction

1 signal

ground

Ignition circuit shield

Ground shield for ignition circuit monitoring

output

Fuel consumption (KVA signal)

To instrument cluster

output

Crankshaft rpm

Engine speed (TD) signal to instrument cluster

output

A/C compressor control

A/C compressor relay terminal 85

vacant

output

Ignition coil control, cyl. 1

Primary signal, ignition coil 1

output

Ignition coil control, cyl. 2

Primary signal, ignition coil 2

output

Ignition coil control, cyl. 3

Primary signal, ignition coil 3

vacant

input

Power supply

Battery voltage from main relay (terminal 87a)

ground

Ground

Ground for ignition control

input

Power supply (terminal 15)

Battery voltage with key on or engine running

input

Ignition timing intervention

From A/T control module

vacant

output

Throttle position sensor (TPS)

Voltage supply to TPS (5 VDC)

input

Programming voltage

Data link connector

vacant

input

A/C on signal

From integrated climate control module

input

A/C pressure signal

From integrated climate control module via A/C pressure switch

input

On-board computer

Drive-away protection enable (starter immobilization relay)

vacant

input

Knock sensor #2 (cyl . 4, 5, 6)

Knock sensor #2 signal

input

Knock sensor #1 (cyl . 1, 2, 3)

Knock sensor #1 signal

ground

Ground

Ground for knock sensors and shields

vacant

input

Throttle position signal

vacant

Throttle position sensor (TPS) -

vacant

input

Intake air temperatura

Intake air temperatura sensor (0-5 VDC)

input

Engine coolant temperature

Engine coolant temperature sensor (0-5 VDC)

vacant

input

Automatic transmission gear positionlneutral safety switch

A/T park or neutral position signal

vacant

input

Diagnostic connector (RxD)

Diagnostic RxD (receive) signal to pin 15 in Data link connector

input/output

Diagnostic connector (TxD)

Diagnostic TxD (transmit) signal to pin 20 in Data link connector

ECM PIN ASSIGNMENTS

130-34

FUEL INJECTION

i Signal

Table k. ECM Pin Assignment-Bosch DME M5.2 1 Signal 1 Component/function

output

Oxygen sensor (monitoring sensor) heater

Oxygen sensor heater control (switched ground)

output

Idle speed control valve

Pulsed ground-close signal (see also pin 29)

output

Fuel injector control, cyl. 1

Pulsed ground (injection pulse width in ms) cyl. 1

output

Fuel injector control, cyl. 4

Pulsed ground (injection pulse width in ms) cyl. 4

not used

ground

Ground

Ground for fuel injector output stage

not used

1 output

1 Check Engine

1 Instrument cluster, Check Engine lamp

not used

input

Electronic immobilizer control (EWS II)

Electronic immobilizer control (EWS II) module

output

Automatic climate control

Automatic climate control, to evaporator controlier

not used

input

Intake air temperature

Intake air temperature Signal

input

Mass airflow meter

Intake air signal

not used

input

Oxygen sensor (monitoring sensor)

Oxygen sensor control

output

Crankshaft/rpm sensor

Crankshaft/rpm sensor control

input

Camshaft position sensor

Camshaft position signal

output

Ignition coil control, cyl. 3

Primary signal, ignition coil 3

output

Ignition coil control, cyl. 4

Primary signal, ignition coil 4

not used

input

Power supply (terminal 30)

Battery voltage (B+) at al¡ times

input

Main relay control

Main relay activation (terminal 85)

ground

Ground

Ground for ECM and sensor shielding

output

Idle speed control valve

Pulsed ground-open signal (see also pin 2)

output

Oxygen sensor (monitoring sensor) heater

Oxygen sensor heater control (switched ground)

output

Fuel injector control, cyl. 3

Pulsed ground (injection pulse width in ms) cyl. 3

output

Fuel injector control, cyl. 2

Pulsed ground (injection pulse width in ms) cyl. 2

I not used

ground

Ground

Ground for ECM/ output stages

not used

input

A/C compressor relay

A/C compressor relay control

not used

input

Knock sensor #2 (cyl . 3,4)

Knock sensor #2 signal

not used

input

Vehicle speed

Vehicle speed signal from instrument cluster

not used

output

Throttle position sensor (TPS)

Throttle position reference signal

ECM PINASSIGNMENTS

FUEL INJECTION

130- 35

Table k. ECM Pin Assignment-Bosch DME M5.2 (continued) Pin

I Signal

1 Componentltunction

1 Signal

I output

I Mass air flow meter

output

I Intake air Signal

Oxygen sensor (monitoring sensor)

Oxygen sensor control

not used

output

Ignition coil control, cyl. 1

Primary signal, ignition coil 1

output

Ignition coil control, cyl. 2

not used

Primary signal, ignition coil 2

not used

input

Throttle position sensor

input

Throttle position Signal

Power supply

Battery voltage from main relay (terminal 87)

ground

Ground

Ground for ECM

input

Power supply (terminal 15)

Battery voltage with key on or engine running

output

Activate cooling fan (man . trans.) control

Normal speed relay

not used

input

Programming voltage

output

Evaporative emission valve

Programming voltage via data link connector, pin 18

vacant

output

Fuel pump relay

Fuel pump relay control

not used

Evaporative emission valve control

not used

input

Signal above 80°C (man . tran .)

Double temperature switch

input

Automatic climate control

Automatíc climate control

input

Knock sensor #1 (cyl . 1,2)

Knock sensor #1 Signal

ground

Ground

Ground for analog signals and knock sensors

not used

input

Engine coolant temperature sensor

Engine coolant temperatura Signal

not used

output

Oxygen sensor (regulating sensor)

Oxygen sensor control

input

Crankshaft/rpm sensor

Crankshaft position/rpm Signal

input

ABS or traction control

ABS or AST control

input

Engine speed

Engine speed Signal

not used

input

On-board computar

From On-board computer (terminal 4)

not used

input

Diagnostic connector (RxD)

Diagnostic RxD (receive) signal to pin 15 in Data link connector

output

Diagnostic connector (TxD)

Diagnostic TxD (transmit) signal to pin 17in Data link connector

ECM PIN ASSIGNMENTS

130- 36

FUEL INJECTION

Table I. ECM Pin Assignment-Siemens DME MS 41 .1 Pin

1 Signal

1 Componentffunction

1 Signal

output

Ignition coil control, cyl. 2

Primary signal, ignition coil 2

output

Ignition coil control, cyl. 4

Primary signal, ignition coil 4

output

Ignition coil control, cyl. 6

Primary signal, ignition coil 6

ground

Ground

output

Fuel injector control, cyl. 2

Pulsed ground (injection pulse width in ms) cyl. 2

output

Fuel injector control, cyl. 1

Pulsed ground (injection pulse width in ms) cyl. 1

output

Mass air flow meter

Mass air meter signal

input

Mass air flow meter

Mass air meter signal

output

Instrument cluster

Fuel consumption signal

output

Engine coolant temperature (ECT) sensor

ECT signal

output

Fuel tank pressure sensor

Fuel tank pressure sensor control

input

Throttle position sensor (TPS)

Throttle position signal

input

Intake air temperature (IAT) sensor

Intake air temperature signal

Traction control

AST module

input

Automatic climate control

input

Electronic immobilizer control (EWS II)

Electronic immobilizer control (EWS II) module

Automatic climate control

Automatic climate control Instrument cluster

15 16 17 18 19 20

Instrument cluster

output

Camshaft actuator (VANOS solenoid) control Camshaft actuator (VANOS solenoid), switched ground

output

Fuel injector control, cyl . 3

Pulsed ground (injection pulse width in ms) cyl. 3

Fuel injector control, cyl. 6

Pulsed ground (injection pulse width in ms) cyl. 6

Fuel injector control, cyl. 4

Pulsed ground (injection pulse width in ms) cyl . 4

output

Oxygen sensor heater control

Oxygen sensor heater ground

input

Power supply (terminal 30)

Battery voltage (B+) at all times

output

Idle speed control valve

Pulsed ground-open signal (see also pin 53)

ground

Ground

output

Ignition coil control, cyl. 1

Primary signal, ignition coíl 1

output

Ignition coil control, cyl. 3

Primary signal, ignition coil 3

output

Ignition coil control, cyl . 5

Primary signal, ignition coil 5

ground

Ground

output

Fuel injector control, cyl. 5

Pulsed ground (injection pulse width in ms) cyl. 5

ground

Ground

output

Secondary air injection

Secondary air injection pump relay control

output

Engine speed output

Engine speed signal

ground

Knock sensor

Shielding for knock sensors

output

Intake air temperature sensor (IAT Sensor) Engine coolant temperature (ECT) sensor

Voltage supply to IAT sensor and ECT sensor

output

Crankshaft position sensor (Hall effect)

Crankshaft position sensor control

ground

Camshaft position (CMP) sensor

Shielding for CMP sensor

output

Throttle position sensor (TPS)

TPS ground

input

Camshaft position/rpm sensor

Camshaft position/rpm sensor control

output

Throttle position sensor (TPS)

Voltage supply to TPS (5 VDC)

Traction control

AST module

Instrument cluster

45 46

ECM PINASSIGNMENTS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

FUEL INJECTION

130- 37

Table I. ECM Pin Assignment-Siemens DME MS 41 .1 (continued) Pin

I Signal

I Component/function

1 Signal

48 49

input

Crankshaft position sensor (Hall effect)

input

Power supply (terminal 15)

Crankshaft position sensor control

output

Solenoid valve (running losses)

output

Carbon canister valve

vacant

output

Idle speed control valve

input

Power supply

vacant

Battery voltage with key on or engine running Running losses Carbon canister valve control Pulsed ground-close signal (see also pin 29) Battery voltage from main relay (terminal 87)

input

Knock sensor (cyl . 1-3)

output

Knock sensor (cyl . 1-3)

input

Knock sensor (cyl . 4-6)

Knock sensor input Signal

input/output

Diagnostic connector (TxD)

output

Oxygen sensor heater (monitoring sensor)

Diagnostic TxD (transmit) signal to pin 18 in Data link connector

output

Secondary air injection

output

Knock sensor (cyl . 4-6)

input

Camshaft position/rpm sensor

Camshaft position/rpm sensor control

input

Camshaft position/rpm sensor

Camshaft position/rpm sensor control

output

Oxygen sensor

Oxygen sensor reference voltage

output

Evaporative purge valve control

output

Pulsed ground with engine at normal temperature and varying engine load

Fuel pump relay control

Fuel pump relay switches with engine running or cranking (crankshaft position signal must be present for relay switchover)

vacant

output

Oxygen sensor heater (regulating sensor)

Oxygen sensor heater ground

output

Oxygen sensor (monitoring sensor)

Oxygen sensor reference voltage

input

Main relay control

Main relay activation (terminal 85)

output

A/C compressor control

A/C compressor relay control

input

Oxygen sensor

Oxygen sensor signal

not used

input

Oxygen sensor (regulating sensor)

Oxygen sensor signal

input

Oxygen sensor (monitoring sensor)

Oxygen sensor signal

output

Oxygen sensor (regulating sensor)

Oxygen sensor reference voltage

Traction control

AST module

Traction control

AST module

Traction control

AST module

Knock sensor input Signal Knock sensor control

Oxygen sensor heater ground

Secondary air injection control valve Knock sensor control

output

Crankshaft position sensor (Hall effect)

Crankshaft position sensor control

vacant

output

Automatic transmission

Automatic transmission control module

input

Automatic transmission

Automatic transmissíon control module

input

Power supply

Battery voltage from main relay (terminal 87)

input/output

Diagnostic connector (TxD)

Diagnostic TxD (transmit) signal to pin 17 in Data link connector

ECM PIN ASSIGNMENTS

FUEL TANK AND FUEL PUMP

160-1

160 Fuel Tank and Fuel Pump GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160-1 FUEL TANK AND LINES . . . . . . . . . . . . . . . 160-2 Fuel tank, draining . . . . . . . . . . . . . . . . . . . . . 160-2 Fuel tank, removing and installing . . . . . . . . . 160-3 Fuel Tank Evaporative Control System . . . . . 160-4

FUEL LEVEL SENDERS . . . . . . . . . . . . . . . 160-4 Fuel level senders, testing . . . . . . . . . . . . . . . 160-5 Fuel leve¡ sender and fuel pump (right side), \removing and installing . . . . . . 160-5 Fuel leve¡ sender (left side), removing and installing . . . . . . . . . . . . . . . . 160-6

FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 160-6

Operating fuel pump for tests . . . . . . . . . . . . . .160-6 Fuel Pump Electrical Tests . . . . . . . . . . . . . . . 160-7 Fuel pump electrical circuit, testing . . . . . . . . . 160-7 Fuel pump power consumption, testing . . . . . . 160-7 Fuel Delivery Tests . . . . . . . . . . . . . . . . . . . . . 160-8 Relieving fuel pressure and connecting fuel pressure gauge . . . . . . . . . . . . . . . . . . . 160-8 System pressure, testing . . . . . . . . . . . . . . . . . 160-9 Fuel delivery volume, testing . . . . . . . . . . . . . 160-10 TABLES a. Fuel Leve¡ Sender Resistances . . . . . . . . . . . . . . . .160-5 b. Fuel Pump Current . . . . . . . . . . . . . . . . . . . . . . . . . 160-8 c. Fuel Pressure Specifications . . . . . . . . . . . . . . . . . 160-10 d. Fuel Pump Delivery Specifications . . . . . . . . . . . . 160-10

Fuel Pump Fuse and Relay . . . . . . . . . . . . . . 160-6

GENERAL This repair group covers service information specifically for the fuel supply system . Information on the fue¡ injection system is covered in 130 Fuel Injection. NOTEFue¡ filter replacement is covered in 020 Maintenance

Program.

WARNING " The fuel system is designed to retain pressure even when the ignition is off. When working with the fuel system, loosen the fuel lines slowly to allow residual fuel pressure to dissipate gradually. Avoid spraying fuel. " Before beginning any work on the fuel system, place a tire extinguisher in the vicinity of the work area. " Fuel is highly flammable. When working around fuel, do not disconnect any wires that could cause electrical sparks . Do not smoke or work near heaters or other tire hazards. " Always unscrew the fuel tank cap to release pressure in the tank before working on the tank or fines .

The cautions and warnings on this page should be ob served when servicing the fuel system. CAUTION" Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viü. " Before making any electrical tests with the ignition tumed on, disable the ignition system as described in 120 Ignition System . Be sure the battery is disconnected when replacing components. " To prevent damage to the ignition system or the electronic fuel system components, including the control unit, aiways connect and disconnect wires and test equipment with the ignition off. " Cleanliness is essential when working with the fuel system. Thoroughly clean the fuel fine unions before disconnecting any of the fines. " Use only clean tools . Keep removed parts clean and sealed or covered with a clean, lint-free cloth, especially if completion of the repair is delayed. " Do not move the car while the fuel system is open.

" Do not use a work light near any fuel. Fuel may spray onto the hot bulb causing a tire.

" Avoid using high pressure compressed air to blow out fines and componente . High pressure can rupture infernal seals and gaskets .

" Make sure the work area is properly ventifated.

" Always replace seals and O-rings. GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

160-2

FUEL TANK AND FUEL PUMP

1 . Filler pipe 2 . Filler pipe grounding tab 3. Vent pipe 4. Threaded collar 5. Rubber ring seal 6 . Fuel pump 7 . Left side fuel leve¡ sender (models built from 1/95) 8 . Right side fuel leve¡ sender 9 . Left side fuel leve¡ sender with fuel compensating siphon pump (models built up to 1/95)

0011943

10 . Fuel compensating siphon pump and hose assembly (models built from 1/95) 11 . Fuel tank 12 . Tank support strap 13 . Bolt-tighten to 23 Nm (17 ft-Ib) 14 . Fuel expansion tank 15 . Fuel tank pressure sensor (OBD II)

Fig . 1 . E36 fuel tank assembly.

FUEL TANK AND LINES

Fuel tank, draining

The plastic fuel tank is mounted beneath the center of the car (beneath rear seat) . Mounted in the fuel tank are the fuel pump and fuel leve¡ sending units . Connecting lines for the evaporative emission control system and expansion tank are also attached to the tank. When performing the procedures that follow, refer to Fig . 1 .

The fuel tank should be drained into an approved storage unit or another car's fuel tank.

Fuel tank capacity for E36 modeis

" All ex . 1996 M3 (3 .0 L) . . . . . . . . . . 65 liters (17 .0 gal) " 1996 M3 (3 .0 L) modeis . . . . . . . . .62 liters (16 .4 gal)

WARNING -

" Before removing the tank, be sure that afl hot components such as the exhaust system, are

completely cooled down.

" Fuel may be spilled. Do not smoke or work near heaters or other Pire hazards. 1 . Disconnect negative (-) cable from battery. CAUTIONPrior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on paga vi¡¡.

FUEL TA NKAND LINES

FUEL TANK AND FUEL PUMP 2. Remove fuel tank filler cap. 3. Remove rear seat cushion and pull back insulation mats to expose fuel tank access covers . See Fig. 2.

160- 3

NOTE-

" If necessary, push fuel level sender arm toward fuel pump assembly to facilitate removal. " BMW special tool no. 16 1 020 should be used to remove and install the threaded collar. Damage to the collar may result if the special tool is not used. " Pump out contents of each tank lobe using approved pumpinglextraction equipment and flexible fuel-grade hose . WARNING Fuel may be spilled. Do not smoke or work near heaters or other fire hazards.

7. Installation of sending units is reverse of removal, noting the following: " Use new sealing rings when installing pump/sending unit assemblies . " Be sure that fuel line connections point in same direction as they carne out. " Fill tank and check for leaks by running engine. uui3140

Fig. 2. Right side fuel tank access cover under rear seat cushion.

4. Remove right and left access covers to expose fuel hoses and electrical connections at tank . 5. Label fuel hoses. Then disconnect hoses and harness connectors from fuel sending units and fuel pump. See Fig. 3.

CA UTION-

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

Fuel tank, removing and installing 1 . Disconnect negative (-)cable from battery: CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

2. Remove fuel tank filler cap and drain tank as described earlier. 3. Working in left access tank access hole (under rear seat cushion), remove vent pipe from tank . 4. Working inside car, disconnect parking brake cable ends from parking brake lever. See 340 Brakes . 5. Working underneath car, gently pry fuel lines away from retaining bracket in front of tank . Remove clamps and disconnect fuel hoses as shown in Fig. 4. ooisiai Fig. 3. Fuel pump/fuel level sender assembly in top of fuel tank (right side shown) . Disconnect supply hose (A), return hose (B) and harness connector (C). 6. Unscrew threaded collars from fuel tank . Slowly withdraw fuel sender assemblies from tank, allowing fuel to drain off.

6. Remove exhaust system and heat shield as described in 180 Exhaust System . See Fig. 5. 7. Remove driveshaft . See 260 Driveshaft . 8. Pull parking brake cables backward away from bottom of fuel tank, disengaging them from brackets as needed .

FUEL TANKAND LINES

160-4

FUEL TANK AND FUEL PUMP CAUTION" Before starting the engine, fill the fuel tank with at least 1 .5 gallons (5 liters) of fuel to prevent damaging a dry fuel pump. " If the filler neck has been removed from the body, be sure to reattach the neck's grounding screw (where applicable). Check electrical resistance between the ground tab and wheel hub. The resistance should be no higher than 0.6 ohms .

Tightening Torques

" Fuel tank to body . . . . . . . . . . . . . . . . 23 Nm (17 ft-Ib) " Hose clamps (10 mm-16 mm día .) . . 2 .0 Nm (18 in-lb)

Fuel Tank Evaporative Control System Fig . 4 . Pinch off supply and retum fuel hoses (arrows) before disconnecting from rigid metal lines .

The fuel tank evaporative control system is used to vent the fuel tank to charcoal canister, which is then purged by engine vacuum during normal engine operatíon . This controls emission of raw hydrocarbons (fuel) to the atmosphere . See Fig . 1 .

A fuel expansion tank, located under the right rear fender, traps overflow fuel and incorporates extra fuel tank plumbing . Starting with 1996 models, OBD II standards require that the fuel tank evaporative control system be monitored for leaks . This is accomplished using the fuel tank pressure sensor, the vent shut off valve, and the evaporative purge valve .

0013143

Fig . 5 . After removing exhaust system, remove heat shield screws (arrows) and heat shield . 9 . Working underneath car, loosen hose clamp and disconnect filler hose. 10 . Support tank from below . Remove tank strap mounting bolts . Lower and remove tank, disconnecting right side vent and other hoses/electrical connectors as necessary. 11 . Installation is reverse of removal . " Always use new seals, gaskets, O-rings, and hose clamps. " Inspect hoses and replace any that are chafed, dried out or cracked . " Inspect heat shield and replace if corroded . " Inspect rubber buffers and liners on fuel tank, support straps and on underside of body. Replace rubber parts that are hardened or damaged .

FUEL LEVEL SENDERS

NOTEOn most early cars (1992-1995), the charcoal canister is in the engine compartment. On later cars, the charcoal canister is under the spare tire in the luggage compartment.

FUEL LEVEL SENDERS The E36 model uses a two-lobed fuel tank and each lobe of the tank has its own fuel level sending unit. The right side fuel leve¡ sender is integrated with the fuel pump . Each sender has a float connected to a variable resistance for fuel leve¡ . When replacing the sender/pump assembly always replace hose clamps, gaskets and O-rings . WARNING When removing the fuel level sender or the fuel pump, the fuel tank should be emptied.

FUEL TANK AND FUEL PUMP Fuel leve¡ senders, testing The left and right fuel leve¡ sending units are wired in series . The fuel gauge receives a signal that is the average of the two input values . 1 . Remove rear seat cushion, lift up insulation mats, and remove both fuel tank access covers . 2. Disconnect white plug on each sending unit . See Fig. 6.

160-5

Fuel leve¡ sender (right side) and fuel pump, removing and installing 1 . Disconnect negative (-) cable from battery. CAUTION Prior to disconnecting the battery, read the battery disconnection cautions glven at the front of this manual on page viii.

2. Drain fuel from tank as described earlier. WARNING Always unscrew the fuel tank cap to release pressure in the tank before working on the tank or fines.

3. Remove rear seat cushion and pull back insulation pad under right side . 4. Remove screws holding right fuel tank access cover. Remove cover. 5. Label fuel hoses. Disconnect hoses and harness connectors from fuel sending unit and fuel pump .

0013187 & 0013194

Fig. 6. Fuel pump/leve¡ sender terminal identification . Check resistance at terminals of white connectors (arrows) . 3. Check resistance value of each sending unit. Values should be the same . 5. If values are different, remove sending units as described below, and check resistance valués across terminals. Table a lists resistance values for senders at various float positions . NOTEThe compensating siphon pump (Fig. 1) maintains the fuel leve¡ between the right and left tank lobes. If the resistances are different between the left and right senders, remove the senders and visually inspect the leve) in each lobe. If the leve¡ is different, check the siphon compensating pump.

Table a. Fuel Leve¡ Sender Resistances Float position

Test result (ohms)

Right side empty

10 ohm t 2

Right side full

250 ohm ± 5

Left side empty

10 ohm t 2

Left side fui¡

250 ohm ± 5

6. Unscrew threaded collar from fuel pumplfuel leve¡ sender. Slowly withdraw assembly from tank, allowing fuel to drain off. See Fig. 7. " If necessary, push leve¡ sender arm toward fuel pump assembly to facilitate removal. NOTE BMW special tool no. 16 1 020 should be used to remove and install the threaded collar. Damage to the collar may result if the special tool is not used WARNING Fuel may be spilled. Do not smoke or work near heaters or other fire hazards.

7. Using a new sealing ring, install pump and sending unit, being sure that fuel line connections point in same direction as they carne out. 8. Reconnect harness connector and hoses. Fill tank and check for leaks by running engine . Insta¡¡ access cover and its mounting screws . Reconnect negative (-) cable to battery. CAUTION Before starting the engine, fill the fuel tank with at least 1 .5 gallons (5liters) of fuel. The pump will be damaged if you run it without fuel.

FUEL LEVEL SENDERS

160-6

FUEL TANK AND FUEL PUMP Fuel PUMP re ay

DM E main relay

aoo o ~a aao ó 0

0013034,

Fig. 8. Fuel pump relay location in power distribution box. The DME engine control module (ECM) and the DME main relay supply powerto the coi¡ side of the fuel pump relay. During starting, the fuel pump runs as long as the ignition switch is in the start position and continues to run once the engine starts . If an electrical system fault interrupts power to the fuel pump, the engine will not run . Fig. 7. Fuel sender and pump assembly.

0013142

Fuel leve¡ sender (left side), removing and installing The procedure for removing and replacing the left side fuel leve¡ sender is similar to that used for the right side . There is no fuel pump on the left side.

FUEL PUMP The electric fuel pump ís mounted in the fuel tank in tandem with the right side fuel leve¡ sender . The fuel pump delivers fuel at high pressure to the fuel injection system . A pressure regulatormaintains system pressure . The quantity of fuel supplied exceeds demand, so excess fuel retums to the fuel tank via a retum líne . See 130 Fuel Injection for more information on system pressure and the fuel pressure regulator. NOTE -

Fuel pump removal procedures are given earlier under

Fuel leve¡ sender (right side) and fuel pump, removíng and installing .

Fuel Pump Fuse and Relay The fuel pump is operated by a fuel pump relay located ín the power distribution box . The fuel pump circuit is protected by fuse no . 18 located in the power distribution box. See Fig 8.

Operating fuel pump for tests To operate the fuel pump for testing purposes without having to run the engine, the fuel pump relay can be bypassed to powerthe pump directly. To run the fuel pump, remove the relay and connect the socket for relay terminal 30 to the socket for relay terminal no. 87 with a fused jumper wire . Relay terminal identification is shown in Fig. 9. After completing the tests, remove the jumper wire . CA UTION-

Relay locations may vary. Use care when identifying relays and when troubleshooting the electrical system at the fuselrelay panel. The fuel pump re¡ay is a four pin relay and has a 1 .5 mm2 red wire at terminal 30 in the relay socket, lf in doubt, consult an authorized BMW dealer.

NOTE-

Thejumper wire should be 1 .5 mm2 (14 ga.) and include en in-fine fuse holder with a 16 amp fuse. To avoid fuselrelay panel damage from repeated connectíng and disconnecting, also include a toggle switch . A heavy-duty jumper, BMW tool no. 613 050, fs also available from en authorized BMW dealer.

If the pump does not run with the jumper installed, the fault could be in the fuel pump or the wiring to the pump . Check the pump and its wiring as described below.

FUEL PUMP

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

FUEL TANK AND FUEL PUMP From Main Relay (+15 power with key in run orstartposition)

160-7

From B+juretion point (batteryvoRageatalltirnes)

' .5 RD/Nrr

1 .5 RD 30

8~T

Fuel Pump Relay

1 .5 GNNI

From Engine Control Module

2.5 GNNI 15

1 Distribution Box

I I_

2 .5 GNNI

Fig. 9.

WIRING COLOR CODE

Fuel pump relay terminal identification .

Fuel Pump Electrical Tests

Fuel Pump (in-tank)

Troubleshooting of any fuel pump fault should begin with checking the fuel pump fuse and the fuel pump relay. The DME main relay should also be checked.

NOTE-

Special tools are requíred for some of the tests described here .

Fuel pump electrical circuit, testing The fuel pump electrical circuit diagram is shown in Fig. 10 .

CAUTION-

Fuseandrelaylocationsmayvary. Usecara when troubleshooting the electrical system at the fuselrelay panel. To resolve problems in identifying a relay, see en authorízed BMW dealer.

1 . Remove rear seat cushion, pull right side insulation mat back to expose fuel tank access cover. Remove cover to expose wiring connections . 2. Remove fuel pump relay and opérate fuel pump as described under Operating fuel pump for tests earlier. Pump should run. Disconnect jumper wire when finished.

3. If fuel pump does not run, disconnect black harness connector from tank sender unit . With jumper wire connected as described in step 2 above, check for positive (+) battery voltage at harness connector terminals. See Fig. 11 .

s áma61 Front Power

BK BR RD YL GN BU VI GY WT PK

Ground (below center console)

BLACK BROWN RED YELLOW GREEN BLUE VIOLET GREY WHITE PINK

0011946

Fig. 10. Fuel pump electrical circuit.

4. If voltage and ground are present, fuel pump is probably faulty. If there is no voltage, check wiring From fuel pump Reay and make sure Reay is functioning correctly.

Fuel pump power consumption, testing NOTE-

" To achieve accurate test results, fhe battery voltage at the connector should be approximately 13 volts. Charge the battery as necessary.

. q higher than normal power consumption usually fin-

dicates a worn fuel pump, which may cause intermittent fuel starvation due lo pump overheating and seizure. The only remedy is pump replacement. Be sure to check that the return fine and the pump pickup are not obstructed before replacing the pump.

1 . Remove rear seat cushion, pull right side insulation mal back to expose fuel tank access cover. Remove cover to expose wiring connections . 2. Disconnect (black) harness connector from fuel pump . 3. Connect an ammeter and an insulated jumper wire between terminals in connector and corresponding pump terminals. See Fig. 12 . FUEL PUMP

160- 8

FUEL TANK AND FUEL PUMP 5 . Compare ammeter reading with specification listed in Table b . Table b . Fuel Pump Current Maximum current consumption

5 .0 amps

Fuel Delivery Tests Checking fuel delivery is a fundamental part of troubleshooting and diagnosing the DME system . Fuel pressure directly influences fuel delivery . An accurate fuel pressure gauge will be needed to make the tests . There are three significant fuel delivery values to be measured :

UU131 tst5

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

" System pressure-created by the fuel pump and maintained by the pressure regulator. " Fuel delivery volume-created by the fuel pump and affected by restrictions, such as clogged fuel filter. " Residual pressure-the pressure maintained in the closed system after the engine and fuel pump are shut off . Procedures for measuring the first two quantities are described here . Residual fuel pressure is checked using the procedure detailed in 130 Fuel Injection .

Relieving fuel pressure and connecting fuel pressure gauge

00131ts7

Fig . 12 . Test fuel pump for current draw by attadhing ammeter and jumper wire as shown . CAUTIONDo not allow the test leads to short to ground. NOTESee 600 Electrical System-General for information on electrical tests using a digital multimeter (DMM) . 4 . Run pump as described in Operating fuel pump for tests.

WARNING " Gasoline is highly flammable and its vapors are explosive. Do not smoke or work on a car near heaters or other fire hazards when diagnosing and repairing fuel system problems. Have a fire extinguisher available in case of an emergency. " When working on an open fuel system, wear suitable hand protection . Prolonged contact with fuel can cause iflnesses and skin disorders. CA UTIONCleanliness is essential when working with fuel circuit components. Thoroughly clean the unions before disconnecting fuel fines To prevent fuel from spraying on a hot engine, system fuel pressure should be relieved before disconnecting fuel lines . One method is to tightly wrap a shop towel around a fuel line fitting and loosen or disconnect the fitting . Measuring fuel pressure requires special tools . Earlier cars use pressure hose with clamps for fuel delivery. These can be attached to a fuel pressure gauge below the intake manifold .

FUEL PUMP

FUEL TANK AND FUEL PUMP NOTE-

On 1996 and later 4-cylinder cars, use BMW special tool 13 6 051 (hose with quick release coupling) to attach pressure gauge to Shraeder valve fitting on top of the M44 fuel rail. See Fig . 13.

160-9

NOTE -

" Use BMW pressure gauge Part No. 133 060, or an equivalent. The fuel pressure gauge should have a range of 0 to 5 bar (0 to 75 psi) and must be securely connected to prevent it from coming loose under pressure .

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

System pressure, testing System pressure is the pressure created by the fuel pump and maintained by the pressure regulator. See Fig . 15 . System pressure is not adjustable .

u012503a

Fig . 13 . Fuel rail showing location of Shrader valve fitting on M44 engine (arrow) . Later model 6-cylinder fuel systems require BMW specíal tool 16 1 050 to release fittings and connect the fuel gauge . See Fig . 14 .

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

CAUTION-

0012699

Fig . 14. Fuel lines at rear of íntake manifold on M52 engine . Use BMW special tool 16 1 050 to release fittings . If the special tools are not available, a length of fuel line and a T-fitting can be installed to the inlet fuel line and connected to a fuel gauge .

The fuel pump is capable of developing a higher pressure than that regulated by the pressure regulator. In the event the fuel pump check valve is faulty (stuck closed), make sure the fuel pressure does not rise aboye 6.0 bar (87 psi) . Damage to the fuel fines or fuel system components could result.

1 . Remove fuel tank filler cap . 2 . Connect in-fine a Tfitting and fuel pressure gauge to outlet hose at fuel pump .

FUEL PUMP

160- 1 0

FUEL TANK AND FUEL PUMP

3. Operate fuel pump as described earlier under Operating fuel pump for tests. Check that fuel pressure corresponds to specifications listed in Table c. " If system pressure is low, repeat test while gradually pinching off return hose . Pressure should rise rapidly. If not, fuel pump is most likely faulty. " If system pressure is too high, check return line from pressure regulator to tank. Check for kinks in hose . Blow compressed air through line to check for blockages . If no faulty can be found, pressure regulator is most likely faulty. See 130 Fuel Injection for testing and replacement procedures . WARNINGFuel under pressure is present during the test. Use hose clamps at all connections.

Table c. Fuel Pressure Specifications Engine

1 Fuel pressure

4-cylinder M42/M44

3 .0 :e 0 .06 bar (43 .5 ± 0 .9 psi)

6-cylinder M50/S50US M52/S52US

3 .0 :j- 0 .06 bar (43 .5 t 0 .9 psi) 3 .5 t 0 .06 bar (51 t 0 .9 psi)

CA UTIONDo not use compressed air above 40 psi to blow out fines or components. Interna¡ damage to components may result.

4. When finished, disconnect pressure gauge.

FUEL PUMP

Fuel delivery volume, testing 1 . Disconnect return line from fuel rail in engine compartment. 2. Connect a length of hose to fitting on fuel rail and place open end of hose in a suitable container for catching fuel (2-quart capacity). 3. Run fuel pump for exactly 30 seconds as described earlier under Operating fuel pump for tests and measure fuel collected . Refer to Table d. Table d. Fuel Pump Delivery Specifications Engine

Delivery rate (30 seconds @ 12V)

4-cylinder M42/M44

0.875 fter (0.93 qt)

6-cylinder M50/S50US M52/S52US

0 .875 fter (0 .93 qt) ~ 1 .12 liter (1 .16 qt)

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

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

RADIATOR AND COOLING SYSTEM

170-1

170 Radiator and Cooling System GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .170-1

Coolant Pump and Thermostat . . . . . . . . . . . . 170-1 Radiator and Expansion Tank. . . . . . . . . . . . . 170-1 Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . 170-2 Warnings and Cautions . . . . . . . . . . . . . . . . . . 170-2

Belt-driven cooling fan, replacing. . . . . . . . . . . 170-7 Electric cooling fan, replacing . . . . . . . . . . . . . 170-8 Auxiliary cooling fan, replacing . . . . . . . . . . . . 170-8 Thermostat, replacing . . . . . . . . . . . . . . . . . . . 170-9 Coolant pump, replacing . . . . . . . . . . . . . . . . 170-10

TROUBLESHOOTING . . . . . . . . . . . . . . . . . .170-2

RADIATOR SERVICE . . . . . . . . . . . . . . . . . . 170-11

Cooling System Pressure Test . . . . . . . . . . . . 170-3 Thermostat Quick Check . . . . . . . . . . . . . . . . 170-3 Temperature Gauge Quick Check . . . . . . . . . 170-3 Cooling fan, testing . . . . . . . . . . . . . . . . . . . . . 170-4

COOLING SYSTEM SERVICE . . . . . . . . . . 170-5 Coolant, draining and filling . . . . . . . . . . . . . . . 170-5 Cooling system, bleeding (radiator with integral expansion tank) . . . . . 170-6

Radiator, removing and installing . . . . . . . . . . 170-11

TABLES a. Coolant Temperature Sensor Wire Colors . . . . . . . . 170-3 b. Auxiliary Cooling Fan Switching Temperatures . : . .170-4 c. Auxiliary Cooling Fan Temperature Switch Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170-5 d. Cooling System Capacities . . . . . . . . . . . . . . . . . . . 170-6

GENERAL This section covers repair and troubleshooting information for the engine cooling system . For heater core and related heating and air conditioning components, see 640 Heating and Air Conditioning .

Coolant Pump and Thermostat A centrifuga¡-type coolant pump is mounted to the front of the engíne . The belt-driven pump circulates coolant through the system whenever the engíne is running. A thermostat controls the flow of coolant into the radiator. When the engíne is cold the thermostat is closed so coolant bypasses the radiator, recirculating from the engíne directly back to the pump . When the engíne reaches operating temperature, thethermostat opens and coolant circulates through the whole system including the radiator .

Radiator and Expansion Tank The radiator is a crossflow design . A translucent expansion tank provides for coolant expansion at higher temperatures and easy monitoring of the coolant leve¡. On 4-cylinder modeis, the radiator expansion tank is integral with the radiator. See Fig. 1 .

A. Expansion tank B. Radiator drain screw

C. Dual temperature fan switch

Fig. 1 . Radiator assembly with integral expansion tank (4-cylinder engine). On 6-cylinder models, a stand alone expansion tank is used . On cars with automatic transmission, ATF is circulated through an additional heat exchanger (ATF cooler).

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

170-2

RADIATOR AND COOLING SYSTEM

Cooling Fans

TROUBLESHOOTING

Belt-driven cooling fan. The primary cooling fan is beltdriven . It is mounted to the front of the coolant pump through a fan clutch . The fan clutch is a viscous fluid coupling that controls the speed of the fan based on engine compartment temperature .

Most cooling system faults can be grouped into one of three categories :

Electric cooling fan . Models with M44 engine and standard transmission substitute an electric fan for the belt-driven viscous fan. This is attached to the rear of the radiator and controlled via the DME 5.2 engine management system . NOTE-

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

Auxiliary cooling fan. In al¡ models a two-speed electric auxiliary cooling fan is mounted behind the front grill and in front of the radiator . This fan is primarily used for the A/C system, but also operates when the coolant temperature exceeds a predetermined leve¡.

Warnings and Cautions The following warnings and Cautions should be observed when working on the cooling system . WARNING " At normal operating temperature the cooling system is pressurized. Allow the system to cool as long as possible before opening-a minimum of an hour-then release the cap slowly to allow sale release of pressure. " Releasing the cooling system pressure lowers the coolants boiling point and the coolant may boíl suddenly. Use heavy gloves and wear eye and lace protection to guard against scalding . " Use extreme care when draining and disposing of engine coolant. Coolant is poisonous and lethal to humans and pets. Pets are attracted to coolant because of its sweet smell and taste . Consult a veterinarian immediately if coolant is ingested by an animal. CAUTION" Avoid adding cold water to the coolant while the engine is hot or overheated. If it is necessary to add coolant to a hot system, do so only with the engine running and coolant pump tuming. " Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii.

TROUBLESHOOTING

" Cooling system leaks " Poor coolant circulation " Radiator cooling fan faults When investigating the cause of overheating or coolant loss, begin with a visual inspection . Be sure to check the condition and tension of the coolant pump drive belt . Check hoses for cracks or softness . Check clamps for looseness. Check the coolant leve¡ and check for evidence of coolant leaks from the engine . Check that the radiator fins are not blocked with dirt or debris . Clean the radiator using low-pressure water or compressed air. Blow outward, from the engine side out. Inspect the coolant pump by first removing the drive belt from the pump . Firmly grasp opposite sídes of the pulley and check for play in all directions. Spin the pulley and check that the shaft runs smoothly. NOTE-

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

The cooling system becomes pressurized at normal operating temperature, which raises the boiling point of the coolant. Leaks may prevent the system from becoming pressurized, allowing the coolant to boil at a lowertemperature . If visual evidence is inconclusive, a cooling system pressure test can help to pinpoint hard-to-find leaks. If the cooling system is full of coolant and holds pressure, the next most probable cause of overheating are: " Faulty radiator fan " Loose or worn drive belt " Failed thermostat or coolant pump " Clogged/plugged radiator or coolant passages . NOTE -

" Some early style coolant pumps were fitted wíth fiberlplastic type impellers . Over time, this impeller can wear away and result in overheating. The plastic impeller can also slip or free-wheel on the pump shaft. If the engine overheats and no other faults can be found, the old style impeller may be the cause of the problem. " Only pumps with the updated metal impeller should be used for replacement.

RADIATOR AND COOLING SYSTEM

Cooling System Pressure Test A cooling system pressure test is used to check for internal leaks. Some of the common sources of internal leaks are a faulty cylinder head gasket, a cracked cylinder head, or a cracked cylinder block. To do a cooling system pressure test, a special pressure tester is needed .

170-3

If the engine overheats and no other cooling system tests indicate trouble, the radiator may have some plugged passages that are restricting coolant flow .

Temperature Gauge Quick Check The coolant temperature sensor is located on the intake manifold (left) side of the cylinder head, under the intake manifold runners. See Fig. 2.

WARNING At normal operating temperature- the cooling system is pressurized. Allow the system to cool before opening . Release the cap slowly to allow sale retease of pressure.

With the engine cold, instan a pressure tester to the expansion tank . Pressurize the system to the specification listed below. Pressure should not drop more than 0.1 bar (1 .45 psi) for at leakt two minutes. If the pressure drops rapidly and there is no sign of an externa¡ leak, the cylinder head gasket may be faulty . Consider a compression test as described in 100 Engine-General . The screw-on type expansion tank cap should also be tested using a pressure tester and the correct adapter. Cooling System Test Pressure " Radiator test pressure . . . . . . . . . . 1 .5 bar (21 .75 psi) " Radiator cap test pressure . . . . . . . . . . . 2 bar (29 psi) U.¡ig .v

CA UTIONExceeding the speclfied test pressure could damage the radiator or other system components .

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

Carefully inspect the radiator cap for damage . Replace a faulty cap or a damaged cap gasket .

In early models, the engine coolant temperature (ECT) sensor for the fuel injection and the coolant temperature gauge sender are located side by side .

Thermostat Quick Check To check if the thermostat is opening and coolant is circulating through the radiator, allow a cold engine to reach operating temperature (temperature gauge needie approximately centered). Shut off engine . Feel the top radiator hose . If the hose is hot to the touch, the coolant is probably circulating correctly. If there are any cool areas in the hose or radiator, coolantflow to the radiator is probably restricted . Check for a faulty thermostat or a plugged radiator. NOTEA thermostat that is stuck open will cause the engine to warm up slowly and run below normal temperature at highway speed. A thermostat that is stuck closed will restrict coolant flow to the radiator and cause overheating .

In later models, the ECT sensor and the gauge sender are combined into one sender unit . For wire colors refer to Table a.

Table a. Coolant Temperature Sensor Wire Colors Function Two sensors: Temperature gauge sender ECT sensor One sensor : Temperature gauge sender ECT sensor

Sensor location

Terminal number

Wire colors

Rear

1 2 1 2

Brown/violet Brown/yellow Brown/red Brown or Brown/black

1 2 3 4

Brown/yellow Brown/violet Brown/red Brown/black or Grey/black

Front

Dual sensor

TROUBLESHOOTING

170-4

RADIATOR AND COOLING SYSTEM

A quick test at the coolant temperature gauge sender can determine if the gauge is functioning correctly. lf the gauge needie remains at the rest position with the engine warm, remove the harness connector from the sender and jumper the correct terminals in the connector to simulate a high engine temperature . See Table a. Turn the ignition on . If the gauge needle moves upward, the sender is faulty . If the gauge does not respond, the wiring to the gauge is broken (open circuit) or the gauge itself is faulty .

The auxiliary cooling fan comes on when coolant tempera ture exceeds a predetermined leve¡ or whenever the air conditioning is on . A dual-range temperature switch for cooling fan control is mounted on the right side of the radiator . See Fig. 3.

WARNING -

1996 and laten models are OBD 11 compliant. Disconnecting electrical connectors wíth the ignition turned on may set fault codes in the ECM. It is recommended that you leave the diagnosis of faults in the coolant temperature sensor system to the BMW dealer service department which has specialized OBD 11 scan tool equipment.

If the gauge needle reads too high when the engine is cold, remove the harness connector from the sender. Turn the ignition on . lf the gauge needle position does not change, the wiring or the gauge is shorted to ground . If the gauge needle drops, the sender is faulty and should be replaced . When replacing a faulty coolant temperature sender, the gasket ring on the sender should also be replaced . Tightening Torque " Temperature gauge sender to engine 18 Nm (13 ft-Ib)

Fig. 3. Radiator cooling fan temperature switch (arrow). WARNING -

" Use caution when testing the electric cooling fan(s) and coolant temperature switch . Keep hands and wires clear of the fan blades. The cooling fan(s) can run any time the ignition is ON.

Cooling fan, testing NOTEOn M44 engines with manual transmission, the primary electric cooling fan is mounted on the engine side of the radiator and is controlled by the engine control module (ECM) . Troubleshooting this circuit should be left to an authorized BMW dealer with the proper diagnostic equipment

An otherwise sound cooling system may still overheat, particularly with prolonged idling, due to a failure of the coolíng fan(s) . The belt-driven cooling fan is controlled by a temperature dependent viscous clutch . A failed fan clutch may affect air flow through the radiator resulting in overheating or possibly overcooling . With the engine off, check the fan clutch by spinning the fan. The fan should spin on the clutch with some resistance . Check for signs of leaking fluid from the clutch . If the fan freewheels with no resistance, cannot be tu rned by hand, or there are signs of oil leakage, the clutch should be replaced .

TROUBLESHOOTING

0012506

" For greatest safety, coolíng fan and coolant temperature switch tests should be performed on a cold engine with the air conditioning off.

If a faulty thermostat, trapped air, or a restriction in the system is not allowing the coolant to circulate through the radiator, the temperature switch will not close and the auxiliary cooling fan will not run. Before making the tests described below, make sure the thermostat is operating correctly as described earlier. The normal switching temperatures for the dual -speed switch are listed in Table b. Table b. Auxiliary Cooling Fan Switching Temperatures Speed

Switching temperature

Low sp eed High speed

196°F(91°C) 210°F(99°C)

RADIATOR AND COOLING SYSTEM NOTESome cars covered by this manual may have an alternate cooling fan switch with switching temperatures of 176%190W (80%88°C). When replacing the switch check the switching specifications, which should be stamped on the switch body.

170-5

~r~nmm a 0 0

1 . If coolant is circulating at normal operating temperature, but auxiliary cooling fan does not run, disconnect connector from radiator temperature switch and make tests listed in Table c. Table c. Auxiliary Cooling Fan Temperature Switch Tests Wires jumpered

Test conditions

Test resuits

Black/green (terminal 2) and brown (terminal 1)

Ignition ON

Fan runs on low speed

Black/gray (terminal 3) and brown (terminal 1)

I Ignition ON

0013034

Fig. 4. Auxiliary radiator cooling fan low speed relay (1) and high speed relay (2) in power distribution box. (Relay locations may vary.)

Fan runs on high speed

2. If fan runs only when powered directly by jumpered connector and hot coolant is circulating through radiator, radiator temperature switch is most likely faulty. Use a new sealing ring when replacing switch Tightening Torque " Temperature switch to radiator . . . . . . 15 Nm (11 ft-Ib) 3. If auxiliary fan does not run when powered directly, check for battery voltage at temperature switch connector (black/green wire) with ignition on . If battery voltage is not present, check fuses. See 610 Electrical Component Locations. Auxiliary Cooling Fan Circuit Fuses " Fuse16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 amp " Fuse 41 (ex. M44 w/man. trans) . . . . . . . . . . . 30 amp " Fuse 48 (M44 w/man. trans. only) . . . . . . . . . . 40 amp 4. If no faults are found, remove low speed relay and turn ignition ON . See Fig. 4. " Check for power at terminal 30 and terminal 86 of relay socket . " Reinstall low speed relay and repeat test at high speed relay socket . Fix any wiring faults found.

On early production cars (up to 9/92): If fan operates only on high speed and no electrical faults have been found up to this point, use an ohmmeter to check that fan resistor is not electrically open . Resistor is mounted on auxiliary cooling fan housing behind front grille . See Fig. 5. Wiring diagrams for the radiator cooling fan can be found under Electrical Wiring Diagrams .

Fig. 5. Auxiliary radiator fan resistor (arrow).

COOLING SYSTEM SERVICE Coolant, draining and filling 1 . Remove expansion tank cap. Set temperature controls to full warm . WARNING Allow the cooling system to cool before openlng or draining the cooling system .

2. Place 3ra allo beneath radiator drain plug and remove drain plg. ug. See Fig. 6. 3. Place 3-g mlon pail beneath rear of engine blo k. Loosen and re ove engine block coolant drain plug . COOLING SYSTEM SERVICE

170-6

RADIATOR AND COOLING SYSTEM Tightehing Torques " Radiator drain plug to radiator . . . 2-3 Nm (18-27 in-lb) " Engine block drain plug to block . . . . 25 Nm (18 ft-Ib)

Cooling system, bleeding (radiator with integral expansion tank) NOTE -

On radiators with a separate expansion tank, a bleed screw is not provided . The cooling system with separate expansion tank is self bleeding via the vent hose on the expansion tank. Air may become trapped in the system during filling . Trapped air can prevent proper coolant circulation . Whenever the coolant is drained and filled, the system should be bled of trapped air. Fig . 6 . Radiator drain plug (arrow) . WARNING Coolant is poisonous . It is especially lethal to pets . Clean up spills immediately and rinse the area with water.

1 . With engine cold, add coolant to expansion tank until level reaches COLD (KALT) mark on tank .

2. Loosen bleed screw on radiator expansion tank . See Fig. 7.

NOTE -

The block drain plug is located on the exhaust side of the engine, near the reas of the engine. 4 . Reinstall radiator and engine block drain plugs using new sealing washers. Leave heater controis on full warm . 5 . Using a coolant mixture of 50% antifreeze and 50% distilled water, fill system slowly On radiator with integral expansion tank, bleed cooling system as described below.

NOTE-

" Tap water may cause corrosion of radiator, engine and coolant hoses. " Coolant can often be reused provided it is clean and less than two years old. Do not reuse coolant when replacing damaged engine parts. Contaminated coolant may damage the engine or cooling system .

Table d. Cooling System Capacities Engine

j Capacity

4-cylinder

1 6 .5 liters (6 .9 qt)

6-cylinder M50/M52 S50US/S52US

10 liters (10 .6 qt) 10 .5 liters (11 .1 qt)

0011976

Fig . 7. Cooling system bleed screw on radiator (arrow) . Note cold level mark on expansion tank . 3 . M3 models : Loosen bleed screw on thermostat housing . 4 . Set temperature controls in passenger compartment to fui¡ warm and turn ignition on position (do not start engine) .

COOLING SYSTEM SERVICE

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RADIATOR AND COOLING SYSTEM

170-7

5. Slowly add coolant until it spills from bleed screws . When coolant spillíng from bleed screws is free of air bubbies, tighten screws . 6. Run engine until it reaches operatíng temperature . After engine has cooled, recheck coolant level and top up as necessary. CAUTION-

Always use genuine BMW coolant or its equivalent to avoid the formation of harmful, clogging deposits in the cooling system . Use of other antifreeze solutions may be harmful to the cooling system .

Tightening Torque " Radiator bleed screw to thermostat housing . . . . . . . . . . . . . 8 Nm (71 in-lb)

Belt-driven cooling fan, replacing 1 . Using a 32 mm wrench on fan clutch nut, turn wrench quickly in a clockwise direction (working from front of car) to loosen . Spin fan off pump. See Fig. 8.

Fig. 8. Radiator cooling fan nut (arrow). Nut has left-hand threads.

NOTE-

" The radiator cooling fan nut (32 mm wrench) has lefthand threads . " The nut may be difficult to loosen. Use a tool to hold the coolant pump pulley stationary. BMW has a special tool for this purpose (BMW special tool no. 115 030).

2. Remove expansion rivets holding shroud to radiator. See Fig. 9. Remove fan and shroud together. NOTE-

Store the removed fan clutch assembly in an upright (installed) position to prevent loss of clutch fluid.

3. To replace fan clutch, remove fan mounting bolts and separate clutch from fan . 4. Installation is reverse of rernoval .

0013203

Fig. 9. Fan shroud retaining rivet (arrow). Pry out center pin and re move rivet. Rivet design may vary depending on model and model year.

Tightening Torques " Clutch nut to coolant pump (left-hand threads) Wíthout BMW tool no. 11 5 040 . . . . . 40 Nm (29 ft-lb) With BMW tool no . 11 5 040 . . . . . . . 30 Nm (22 ft-Ib) " Fan to viscous clutch . . . . . . . . . . . . . 10 Nm (89 in-lb)

COOLING SYSTEM SERVICE

170-8

RADIATOR AND COOLING SYSTEM

Electric cooling fan, replacing On late 4-cylinder models (M44 engine) with manual transmission, the primary cooling fan is electrically operated and is mounted on the engine side of the radiator. 1 . If necessary, remove cover from top of radiator. See Fig. 10 .

Fig. 11 . Front radiator air shroud fasteners (arrows) .

0013137

0012505

Fig. 10. Aircover in back of radiator. Unclip cover from fan shroud after removing mounting screws. 2. Disconnect fan harness connector at bottom left of radiator. 3. Remove fan shroud mounting screws at left and right side of radiator. Lift fan assembly straight up and off radiator. 4. Installation is reverse of removal. Be sure to align side tabs on fan housíng with retaining tabs on radiator when reinstalling fan. Auxiliary cooling fan, replacing The auxiliary electric cooling fan is mounted behind the front bumper, in front of the A/Ccondenser. There are two versions of auxiliary fans installed, depending on model and engine installed.

Fig. 12. Version 1 auxiliary fan mounting screws (arrows) . NOTE If necessary, remove front bumper or lower engine cover to access electrical harness connector.

TType 1 (u p to 9192)

4. Installation is reverse of removal.

1 . Remove front radiator air shroud . See Fig. 11 .

l) Type 2 (from 9192)

2 . Remove fan mounting screws . See Fig. 12 .

1 . Remove front bumper and radiator grilles. See 510 Exterior Trim, Bumpers.

3. Tilt fan forward. Disconnect electrical harness connector before lifting fan up.

2. Remove fan mounting screws . See Fig. 13 . 3. Angle fan up and forward, disconnecting electrical harness connector behind it . Remove it through bumper opening .

COOLING SYSTEM SERVICE

RADIATOR AND COOLING SYSTEM

170-9

WARNING Allow the cooling system to cool before opening or draining the system . 2 . Remove belt-driven cooling fan and fan shroud as described earlier. 3 . On M52/S52US engines : Unclip wiring duct retaining clips and remove duct from above thermostat housing . Also remove engine front lifting bracket . 4 . Remove thermostat housing from front of engine . See Fig . 15 .

0013146

Fig. 13 . Version 2 auxiliary fan mounting screws (arrows) . Front bumper has been removed . 4 . Installation is reverse of removal .

Thermostat, replacing The coolant thermostat is instalied in a housing at the front of the cylinder head . See Fig . 14 . Fig. 15 . Thermostat housíng shown removed (6-cylinder engine) . 5 . Remove thermostat . Note thermostat direction and orientation before removing . 6 . Insta¡¡ new thermostat and/or thermostat housing using new O-ring and gasket(s) as necessary. NOTESome thermostats have a direction arrow or vent hole near the edge. Install the thermostat so that either the arrow or hole are at the top. oo131ss

Fig . 14 . Coolant thermostat and housíng . NOTEOn M44 engines, the thermostat is integrated into the thermostat housíng. If the thermostat requires replacement, the complete thermostathousing mustbe replaced. 1 . Drain radiator as described above under Coolant, draining and filling .

7 . Installation is reverse of removal . Fill system with coolant as described under Coolant, draining and filling . CAUTION Be sure to reconnect ground wire(s) at thermostat housing mounting bolt, where applicable.

Tightening Torques " Thermostat housing cover to housing or coolant pump . . . . . . . . 10 Nm (89 in-lb) " Engine lifting bracket bolt to thermostat housing (M52/S52US engine)(M8) . . . . . . . . . 22 Nm (17 ft-Ib)

COOLING SYSTEM SERVICE

170-10

RADIATOR AND COOLING SYSTEM

Coolant pump, replacing The engine coolant pump is mounted in the front of the engine on the timing cover. See Fig. 16 .

0011989

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

0013197

Fig. 16 . Coolant pump mounted on timing cover. NOTE-

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

1 . Drain cooling system as described earlier. WARNING Allow cool¡ng system to cool before open¡ng or drain¡ng system .

2. Remove primary cooling fan shroud and cooling fan (belt-driven or electric) as described earlier. 3. Disconnect hoses from thermostat housing . Unbolt thermostat housing from front of cylinder head . 4. Remove coolant pump drive belt . See Fig . 17 or Fig. 18 . NOTE- Mark direction of drive belt rotation if reusing belt. " Severa¡ drive belt and tensioner configurations have been used in E36 models . Refer to 020 Maintenance Program and 640 Heating and Air Conditioning .

5. Remove coolant pump pulley from pump. 6. Remove mounting fasteners from pump .

COOLING SYSTEM SERVICE

Fig. 18 . Drive belt tensioner being released on M52 engine . Pry off tensioner cover and then lever tensioner clockwise (as facing engine) to release belt tension. NOTE-

" The 4-cylinder coolant pump ¡s mounted us¡ng two difterent length bolts . Note where the longer bolt fits during disassembly. " The 6-cylinder coolant pump ¡s mounted on studs and retained by nuts.

7. Insert two screws (M6) in tapped bores and tighten uniformly until pump is free from timing chain cover. See Fig. 19 .

RADIATOR AND COOLING SYSTEM

Fig . 19 . Coolant pump being removed . Thread two M6 bolts (arrows) in evenly to withdraw pump . (Thermostat and hoses have been removed tor visual access .) 8 . Installation is reverse of removal . " Be sure to replace O-ring and gaskets . " Coat O-ring with lubricant during installation .

170-11

0012500

Fig . 20. Cooling fan dual temperatura switch (arrow) on right sido of radiator. 6 . Where applicable, disconnect automatic transmission fluid (ATF) cooler lines from radiator . See Fig . 21 .

Tightening Torque " Coolant pump to timing chain cover M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (17 ft-Ib) " Coolant pump pulley to coolant pump . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb)

RADIATOR SERVICE Radiator, removing and installing 1 . Drain radiator as described earlier. WARNING Allow cooling system to cool before opening or draining system . 2 . Remove primary cooling fan (belt-driven or electric) as described earlier. 3 . Disconnect cooling fan and leve¡ sensor harness connectors from bottom of radiator, where applicable 4 . Disconnect harness connector from auxiliary fan dual temperature switch . See Fig . 20 . 5 . Disconnect all coolant hoses from radiator.

Fig. 21 . Automatic transmission fluid (ATF) linos at radiator. 7 . Carefully pry out radiator retaining clips from top of radiator . See Fig . 22 . 8 . Pul¡ radiator up and out of car. NOTEThe radiator rests on two rubber mounts. Check that the mounts do not stick to the bottom of the radiator. RADIATOR SERVICE

170-12

RADIATOR AND COOLING SYSTEM

Fig. 22 . Radiator retaining clip being removed . Push down and pulí screwdriver forward to release clip . 9 . Installation is reverse of removal . " Fill radiator and cooling system as described under Coolant, draining and filling . " Check ATF leve¡ and, if necessary, top up. See 240 Automatic Transmission .

RADIATOR SERVICE

EXHAUST SYSTEM

180-1

180 Exhaust System GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180-1 EXHAUST SYSTEM REPLACEMENT . . . . 180-1

GENERAL

Exhaust system, removing and installing . . . . .180-3 Exhaust manifolds, removing and installing . . .180-5 T

WARNING -

The exhaust system is designed to be maintenance free, although regular inspection is warranted due to the harsh operating conditions . Under normal conditions, the catalytic converter does not require replacement unless it is damaged. On 1996 and later cars, a pre- and post-catalytic converter oxygen sensor is used at each catalytic converter. Be sure to take care when removing the system not to damage the sensors . See 130 Fuel Injection for information on testing oxygen sensors. NOTEOn M52 engines, two resonator pípes (short and long) are incorporated into the rear muffler assembly. See Fíg. 1 . An exhaust flap is integrated into the outlet side of the short pipe. The flap is operated by a vacuum actuator via the Siemens MS 41 .1 engine control module). The flap is closed at engine speeds below 2,500 rpm. This allows exhaust gasses to flow through the long resonator pipe and reduce noise. Above 2,500 rpm, the exhaust flap is open (no vacuum applied to the actuator) and allows exhaust gasses to flow through the short pipe for maximum performance.

Exhaust gases are colorless, odorless, and very toxic . Run the engine only ín a well-ventilated area . Immediately repair any leaks in the exhaust system or structural damage to the car body that might allow exhaust gases to enter the passenger compartment.

EXHAUST SYSTEM REPLACEMENT Exhaust system components are detailed in Fig. 2 through Fig. 4. New fasteners, clamps, rubber mounts, and gaskets should be used when replacing exhaust components . A liberal application of penetrating oil to the exhaust system nuts and bolts in advance may make removal easier. WARNING -

" The exhaust system and catalytic converter operate at high temperatures . Allow components to cool before servicing. Wear protectíve clothíng to prevent bums . Do not use flammable chemicals near a hot catalytic converter. " Old, corroded exhaust system components crumble easíly and often have exposed sharp edges. To avoid injury, wear eye protection and heavy gloves when working with old exhaust parts .

0013101

Fig. 1 . Rear muffler (active silencer used on M52 engines) . Vacuum operated flap (A) changes between short and long pipes, depending on engine speed.

EXHAUST SYSTEM REPLACEMENT

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180-2

EXHAUST SYSTEM

32592-95

1. 2. 3. 4. 5.

Front pipe with catalytic convertor Gasket (2) Exhaust manifold Exhaust manifold Manifold gasket

6. 7. 8. 9. 10 .

Bracket Bracket (2) Bracket Bracket Oxygen sensor

11 . 12 . 13. 14. 15 .

Bracket/clamp (2) Rubber mounting ring (2) Flange Gasket (48mm) Gasket (48mm)

16. Rear pipe with muffler 17. Rubber mount 18. Support 19. Bracket

Fig . 2. Exhaust system on 1992-1995 6-cylinder engines . 3251 (M50) exhaust system shown .

a 1. 2. 3. 4. 5. 6.

Exhaust manifold Nut (M10) Gasket (clty. 2) Gasket Nut Bolt (M8X55)

eme°"

:I> - 8a

)l-,malo m~= i

Front pipe with catalytic con- 9 . vertor 10 . 8. Oxygen sensor (regulating) 11 . -tighten to 55 Nm (41 ft-Ib) 8a. Oxygen sensor (monitoring) 12 . -tighten to 55 Nm (41 ft-Ib) 13.

Bolt (M8X90) Compression spring Self-locking nut (M8 -always replace Bracket (rear pipe) Rubber mounting ring (9ty 2)

14. Brackets (rear muffier) 15. Rear muffler and pipe 16. Bracket (transmission) 17. Brackets (transmission)

Fig . 3. Exhaust system on 1996-1998 4-cylinder (M44) engine .1992-1995 4-cylinder engine exhaust system is similar.

EXHAUST SYSTEM REPLACEMENT

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EXHAUST SYSTEM

180-3

0011940

1 . Gaskets 2 . Exhaust manifold

3. Exhaust manifold 4. Oxygen sensor (regulating) Fig . 4 .

5. Front pipe with catalytic converter 6. Oxygen sensor (monitoring) 7 . Nut (M8)

8. Flange 9. Bolt (M8x55) 10 . Rubber mounting ring (48mm) 11 . Rear pipe with mufflers

Exhaust system on 1996-1998 6-cylinder engines. M3 (S50US) exhaust system shown.

Exhaust system, removing and installing

NOTEThe automatic transmission will be supported by the rear crossmember once the brace is removed.

This section covers removing the exhaust system as a complete unit . Once the system is removed from the car, individual pipes and mufflers can be more easily replaced . 1 . With exhaust system fully cold, raise and support car for access to exhaust system . WARNING Do not work under a lifted car unless it is solidly supported on jack stands designed for that purpose . Never work under a car that is supported solely by a jack.

2. Disconnect oxygen sensor connector(s) . NOTE On 1996 and later cars with multiple oxygen sensors, label the oxygen sensor connectors before disconnecting.

Fig . 5 .

Cross brace mounting bolts (arrows) .

3. Loosen and remove bolts holding front exhaust pipes to exhaust manifolds.

5. Disconnect exhaust support bracket assembly from transmission . See Fig. 6.

4. Where applicable, remove support brace from transmission . See Fig. 5.

6. Support exhaust system from below and dísconnect rubber supports/rubber rings from exhaust system . Remove exhaust system from below. See Fig. 7.

EXHAUST SYSTEM REPLACEMENT

180-4

EXHAUST SYSTEM 7 . Installation is reverse of removal . " Where necessary, transfer parts from old system to replacement system . " Coat manifold studs with copper paste before installing nuts . " Where applicable, tighten front pípe with semi-flexible compensator last when installing front pipe to manifolds . " Make sure there is at least 20 mm ( 3/4 in .) of clearance between exhaust system and car body at every point . " Loosely install all exhaust system mounting hardware and hangers before tightening fasteners to their final torque . " On 4-cylinder engines : Tighten center mounting flange nuts evenly until correct dimension is obtained . See Fig . 8 .

Fig . 6 .

Exhaust system support bracket on 6-cylinder engine . Remove bolts (arrows) to separate from exhaust pipe . ri

J%JJ

~~~JJJJ

0011937 1

Fig . 8. On 4-cylinder engines, tighten nuts evenly so that spríngs are preloaded to Dimension A . Fig . 7.

Rubber exhaust system hangers . Remove hanger by prying off bracket (arrows).

NOTETo prevent exhaust system rattles and vibration, preload the rear clamping brackets in the íonaard direction . See Fig. 9.

Tightening Torques " Cross brace to chassis . . . . . . . . . . . 21 Nm (17 ft-Ib) " Exhaust support bracket to transmission . . . . . . . . . . . . . . . . , . 21 Nm (17 ft-Ib) " Exhaust system mounting clamps . . . 15 Nm (11 ft-Ib) " Front exhaust pipe to exhaust manifold M10 nut . . . . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft-Ib) " Front exhaust pipe to rear pipe M8 bolt/nut . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft-Ib) with compression spring . . . . . . . . . . . . . . . . See Fig . 8 " Oxygen sensor to exhaust pipe . . . . . 55 Nm (41 ft-Ib)

EXHAUST SYSTEM REPLACEMENT

EXHAUST SYSTEM

180-5

2. On 1996 and later 6-cylinder engines, disconnect the secondary air check valve and eipe from the exhaust manifold . 3. Unbolt front exhaust pipe(s) from exhaust manifold(s) . 4. Remove exhaust support bracket from transmission . 5. Loosen and remove nuts from exhaust manifolds and remove manifolds. Discard nuts and gaskets.

Dimension A=15mm (0 .60 in .) Fig. 9. Preload rear clamping bracket as specifíed to help prevent system rattling .

Exhaust manifolds, removing and installing Always use new retaining nuts and gaskets when removing and installing the exhaust manifolds. 1 . With exhaust system cold, raise and support car for access lo exhaust system .

NOTEOn cars wíth oxygen sensors mounted in the exhaust manifolds, use care when removing manifolds. To be safe, remove the sensors from the manifolds before removing manifolds.

6. Installation is reverse of removal. " Coat exhaust manifold mounting studs with copper paste before installing new nuts . " Insta¡¡ manifold gaskets with arched side facing manifolds. Tightening Torques " Exhaust manifold to cylinder head 4-cylinder engine (M7 nut) . . . . . . . . 15 Nm (11 ft-Ib) 6-cylinder engine (M7 nut) . . . . . . . . 20 Nm (15 ft-Ib)

WARNING Do not work under a lifted car unfess it is solidly supported on jack stands designed for that purpose. Never work under a car that is supported solely by a jack.

EXHAUST SYSTEM REPLACEMENT

TRANSMISSION-GENERAL

200-1

200 Transmission-General GENERAL

200-1

Manual Transmission . . . . . . . . . . .' . . . . . . . . 200-1 Automatic Transmission . . . . . . . . . . . . . . . . . 200-1 Transmission ID Codes. . . . . . . . . . . . . . . . . . 200-2

TABLES a. Manual Transmission Applications . . . . . . . . . . . . . 200-1 b. Automatic Transmission Applications . . . . . . . . . . . 200-1

GENERAL E36 models are equipped with a longitudinal drivetrain . The transmission is bolted directly to the rear of the engine . A driveshaft connects the output shaft of the transmission to the final drive. The final drive is mounted lo the rear suspension and the body . Individual drive axles with integrated constant velocity joints transfer rotational power to the rear wheels .

Manual Transmission Due to different power characteristics and performance requirements, four different manual transmissions are used in the models covered by this manual . Manual transmission applications are given in Table a. For transmission gear ratio information and repair information, see 230 Manual Transmission . E36 cars with standard transmission use a single-disc clutch with dual-mass flywheel . For further information, see 210 Clutch . Table a. Manual Transmission Applications Model

Fig. 1. ZF-manufactured manual transmission .

Automatic Transmission Four different automatic transmissions are used, depending on model and model year and/or production date . All of the automatic transmissions are electrohydraulically controlled with either four or five forward speeds . Automatic transmission applications are given in Table b .

Year

Engine

Transmission

1992-1995

M42

Getrag S5D 200 G'

For automatic transmission repair information, see 240 Automatic Transmission .

1996-1998

M44

Getrag S5D 250 G

Table b. Automatic Transmission Applications

323is/iC

1998

M52

Getrag S5D 250 G

325ifsriC

1992-1995

M50

Getrag S5D 250 G

3281/isfC

1996-1998

M52

ZF S5D320 Z

1995

S50US

ZF S5D310 Z

1996-1998

S52US

ZF S5D320 Z

318ifisfC

'The 1992 M42 engine maybe fitted with either the Getrag SSD 200 G transmissionor S5D 250 Getrag . TheS5D 200G was discontinued in production in as of 9/92 . This transmission is interchangeable with Getrag S5D 250G.

Model

Year

Engine

318i1is/1C 323isfiC 3251/is/1C

1992-1995 1998 1992-1995

~ M42 M52 M50

3181/isfC 328i/is/1C

11996-1998 1996-1998

M44 M52

1996-1998

S50US S52US

Transmission A4S 310 R A4S 270 R

I A5S 310 Z

GENERAL

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200-2

TRANSMISSION-GENERAL

Transmission ID Codes On both manual and automatic transmissions, the code letterand transmission type numbers should be located on an ID plate attached to the síde of the transmission . Do not rely on numbers cast on the transmission case for identification . In addition, the transmission lubricant varies between transmissions and model years. Fluid application information should be clearly marked on a label on the transmission . On manual transmissions, either ATF (orange label reads ATF-Oil!) or a special BMW lubricant (yellow label reads MTFLT 1) are used . See 230 Manual Transmission . Automatic transmissions are filled with either Dexron III ATF (black trans. type plate reads ATF-Oil!), a special ffetime oil (green trans. type plate reading Life-Time ó1) . See 240 Automatic Transmission . CAUTIONlf in doubt as to the type of fluid installed in a particular transmission, consult and authorized BMW dealer service department for the latest in operating fluids.

GENERAL

Fig. 2. Typical location of ID píate on automatic transmission housing (arrow) . A4S 310R (THM-R1)

CLUTCH

210-1

210 Clutch GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210-1

CLUTCH MECHANICAL . . . . . . . . . . . . . . . . 210-3 Clutch, removing . . . . . . . . . . . . . . . . . . . . . . . 210-4 Clutch, inspecting and installing. . . . . . . . . . . .210-5 Transmission pilot bearing, replacing . . . . . . . 210-6

CLUTCH HYDRAULICS . . . . . . . . . . . . . . . . 210-1 Clutch hydraulic system, bleeding and flushing . . . . . . . . . . . . . . . . . . 210-2 Clutch master cylinder, replacing . . . . . . . . . . 210-2 Clutch slave cylinder, replacing . . . . . . . . . . . 210-3

Table

a. Clutch Disc Diameter . . . . . . . . . . . . . . . . . . . . . . . . 210-3

GENERAL

CLUTCH HYDRAULICS

This repair group covers replacement of the clutch mechan¡cal and hydrauliccomponents . Special tools may be required for some of the procedures . Read the procedure through before beginning a job.

The Clutch is hydraulically actuated by the master and slave cylinders. Clutch disc wear is automatically taken up by the pushrod travel of the slave cylinder, making periodic adjustments unnecessary.

NOTESee 200 Transmission-General for transmission applicatíon information . The major components of the clutch system are shown in Fig. 1 .

Engine flywheel,,

A soft or spongy feel to the clutch pedal, long pedal freeplay, or grinding noises from the gears while shifting can all indicate problems with the Clutch hydraulics . In these circumstances it is best to start with a clutch fluid flush, followed, if necessary, by replacement of the hydraulic parts.

Pressure plate assembly

Clutch

Release bearing

From brake fluid reservoir 0

Flywheel bolt

Transmission input shaft

Bulkhead

Pressure plate release lever

Release lever

Pushrod

Slave cylinder

Clutch master cylinder

6535

Fig. 1. Clutch assembly and hydraufcs. CLUTCH HYDRAULICS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

210-2

CLUTCH

Clutch hydraulic system, bleeding and flushing If the clutch/brake fluid is murky or muddy, or has not been changed within the last two years, the system should be flushed. Flushing the old fluid from the clutch lines is done using a brake system pressure bleeder. 1 . Remove brake fluíd reservoir cap. Using a clean syringe, remove brake fluid from reservoir. Refill reservoir with clean fluid. 2. Attach pressure brake bleeder to fluid reservoír. CA UTION-

9. Open bleeder valve and slowly push slave cylinder pushrod al¡ the way in . Close bleeder valve and slowly release pushrod. Repeat procedure until fluid runs out clear and without bubbles. 10 . Disconnect bleeder hose . Instan slave cylinder lo transmission. Add clean brake fluid to reservoir as necessary. Check clutch operation. Tightening Torques " Clutch slave cylinder to transmission . . . . . . . . . . . . . . . . . . 22 Nm (17 ft lb)

Clutch master cylinder, replacing

Do not exceed 2 bar (29 psi) pressure at the fluid reservoir when bleeding or flushing the hydraulic system.

3. Connect a length of hose from clutch slave cylinder bleeder valve lo a container. See Fig. 2.

The clutch master cylinder is mounted to the pedal assembly, directly above the clutch pedal. 1 . Disconnect negative (-) cable from battery. CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

2. Remove brake fluid reservoir cap. Using a clean syringe, remove brake fluid from reservoir. CA UTION-

Brake fluid is poisonous, highly corrosive and dangerous to the environment. Wear safety glasses and rubber gloves when working with brake fluid. Do not siphon brake fluid with your mouth. Immediately clean away any fluid spilled on painted surfaces and wash with water, as brake fluid will remove point.

0012003

Fig. 2. Clutch slave cylinder bleedervalve on left side of transmission (arrow) .

3. Disconnect fluid supply hose from master cylinder. Place a pan under hose to catch any excess fluid. 4. Working in engine compartment, disconnect fluid line fitting from master cylinder.

4. Open bleeder valve and allow brake fluid to expel until clean fluid comes out free of air bubbles.

5. Working in passenger compartment, remove lower instrument panel trim above pedal cluster.

5. Close bleeder valve and disconnect pressure bleeding equipment from fluid reservoir. Hose on bleeder valve remains connected.

6. Disconnect clutch pedal from clutch master cylinder push rod by removing clevis pin locking clip and slide out clevis pin.

6. Slowly operate clutch pedal about 10 times. Fill reservoir with clean fluid as necessary.

7. Remove master cylinder mounting bolts. See Fig. 3.

7. Unbolt slave cylinder from transmission . 8. Position slave cylinder so that bleeder valve is facing up (highest point) .

8. Installation is reverse of removal. Fill fluid reservoir with clean fluid. Bleed clutch hydraulics as described earlier. Connect negative cable to battery last.

CLUTCH HYDRAULICS

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CLUTCH

210- 3

0012589

Fig. 3 .

Clutch master cylinder mounting bolts .

Tightening Torques " Clutch master cylinder to bulkhead . . 22 Nm (17 ft-Ib) " Fluid line to master cylinder or slave cylinder . . . . . . . . . . . . . . . . . 16 Nm (12 ft-1b)

Clutch slave cylinder, replacing The clutch slave cylinder is mounted on the left side of the transmission . 1 . Remove brake fluid reservoir cap . Using a clean syringe, 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 tip is 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.

0012715

Fig. 4. Clutch slave cylinder mounting bolts (arrows) .

Tightening Torques " Clutch slave cylinder to transmission . . . . . . . . . . . . . . . . . . 22 Nm (17 ft lb) " Fluid line to slave cylinder . . . . . . .17 Nm (10-12 ft lb)

CLUTCH MECHANICAL The transmission must be removed from the engine to access the clutch mechanical components . It is recommended that the clutch disc, pressure plate and release bearing be replaced during a 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 . Table a . Clutch Disc Diameter Model

Diameter

3181/is/iC

215 mm (8 .46 in)

325i/is/iC 323is/iC

228 mm (8 .98 in)

328i/is/iC M3

240 mm (9 .45 in)

CLUTCH MECHANICAL

210-4

CLUTCH

Clutch, removing 1 . Remove transmission from engine . See 230 Manual Transmission .

5. Install a clutch centering tool through clutch assembly to prevent clutch disc from falling out when removing pressure plate. See Fig. 7.

2. Remove release bearing from transmission input shaft. 3. Remove clutch release lever by sliding it out from under spring clip . See Fig. 5.

0012009

Fig. 7. Clutch centering tool (arrow) shown installed through clutch disc and flywheel .

0011581

6. Remove six bolts from perimeter of pressure plate. Remove pressure plate and clutch disc . See Fig. 8.

Fig. 5. Remove clutch release lever by pulling away from spring clip in direction of arrow. 4. Lock flywheel in posítion using a suitable locking tool (BMW Special tool no. 11 2 170, or equivalent) . See Fig. 6.

6529

Fig. 8. Clutch pressure plate mounting bolts (arrows) .

0012008

Fig. 6. Flywheel locking tool (arrow) installed to rear of cylinder block.

CLUTCH MECHANICAL

CLUTCH

210-5

Clutch, inspecting and installing 1 . Inspect clutch disc for wear, cracks, loose rivets, contamination or excessive runout (warping) . Replace if necessary. 2. Inspect flywheel for scoring, hot spots, cracks or loose or worn guide pins . Replace flywheel if any faults are found. WARNING If flywheel is removed from vehicle, use new bolts duríng installation . The old stretch-type bolts should not be reused.

3. Inspect transmission pilot bearing in end of crankshaft . The bearing should rotate smoothly without play. If necessary, replace as described later. 4. Inspect and clean release bearing lever. Apply a thin coat of grease to release bearíng lever contact points . See Fig . 9. Also, lightly lubricate clutch disc splines and transmission input shaft splínes. 5. Install pressure plate and clutch disc . Do not fully tighten bolts. 6. Center clutch disc on flywheel using centering tool (BMW special tool no . 21 2 130 or equivalent) . Refer to Fig. 7.

Fig . 9 .

Clutch release lever lubrication points (arrows) .

Clutch disc

Clutch pressure plate

NOTEBe sure clutch dísc is facing the correct way. The new disc should be marked engine sfde or transmission side. See Fig. 10.

7. Tighten each bolt one turn at a time until pressure plate is fully seated, and then torque to specification . 8. Remove clutch disc centering tool . Remove flywheel locking tool .

0012026

Fig . 10 . Clutch assembly Note clutch disc hub position during installation .

CLUTCH MECHANICAL

210-6

CLUTCH

9. Clean and inspect release bearing guide sleeve on transmission . Install release lever and release bearing. See Fig. 11 .

0011582

Fig. 11 . Clutch release bearing correctly installed on guide sleeve (A). Bearing tabs (B) align with contact points (C) on release lever. 10 . Insta¡¡ transmission . See 230 Manual Transmission . Tightening Torques " Flywheel to crankshaft (use new bolts) M42/M44 engines . . . . . . . . . . . . . . 120 Nm (89 ft-Ib) All others . . . . . . . . . . . . . . . . . . . . . 105 Nm (77 ft-Ib) " Pressure píate to flywheel M8 8.8 grade . . . . . . . . . . . . . . . . . . . 24 Nm (18 ft-Ib) M8 10 .9 grade . . . . . . . . . . . . . . . . . . 34 Nm (25 ft-Ib)

CLUTCH MECHANICAL

Transmission pilot bearing, replacing 1 . Remove clutch as described earlier. 2. Remove transmission pilot bearing from end of crankshaft using BMW special tool no . 11 2 340, or equivalent. 3. Press new bearing finto place using BMW Specíal Tool no . 11 2 350, or equivalent.

MANUAL TRANSMISSION 230-1 230 Manual Transmission Output shaft sea¡, replacing (transmission installed) . . . . . . . . . . . . . . . . .230-4 Input shaft sea¡, replacing (transmission removed) . . . . . . . . . . . . . . . . 230-5

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230-1 TRANSMISSION FLUID SERVICE . . . . . . .230-1 Transmission fluid leve¡, checking . . . . . . . . . 230-2 Transmission fluid, replacing . . . . . . . . . . . . . 230-2

TRANSMISSION REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 230-5 Transmission, removing and installing . . . .. . . 230-6

TRANSMISSION SERVICE . . . . . . . . . . . . . 230-2 Back-up light switch, replacing . . . . . . . . . . . . 230-2 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, including removal and installation of the transmission unit . Internal transmission repair is not covered. Special press tools and procedures are required to disassemble and service the internal geartrain.

The manual transmissions installed in the E36 models are normally filled with automatic transmission fluid (ATF), although alternative lubricants may have been used from the factory, depending on transmission type and model year. For example, transmissions fitted to the M3 models are normally filled with a "lifetime" manual transmission fluid (BMW MTF LT-1) and do not require periodic fluid changes.

Manual transmissions used are based on engine application . Consult 200 Transmission-General for transmission application information . Table a lists gear ratio specifications .

NOTEThe transmission lubricant type can be found on a label on the side of the transmission. Consult an authorized BMW dealer for altemate fluid use and the most-up-todate information regarding transmission operating fluids.

NOTEDo not rely on forged casting numbers for transmission code identification .

Table a. Manual Transmission Gear Ratios Transmission Gear Ratios : 1 st 2nd 3rd 4th 5th reverse

Getrag S5D 200 G 4.23 2.52 1 .66 1 .22 1 .00 4 .04

Getrag SSD 250 G 4 .23 2 .52 1 .66 1 .22 1 .00 4 .04

ZF S5D 310 Z 4 .20 2.49 1 .66 1 .24 1 .00 3 .89

ZF S5D 320 Z 4.20 2.49 1 .66 1 .24 1 .00 3 .89

TRANSMISSION FLUID SERVICE

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230-2

MANUAL TRANSMISSION

Transmission fluid leve¡, checking

4. Install and torque drain plug .

Checking the transmission oil level involves simply removing the side drain plug and inserting a finger into the hole to check the fluid leve¡. lf the fluid leve¡ is up to the bottom of the drain hole (finger is wetted by transmission fluid), the leve¡ is correct.

5. Remove fill plug from side of transmission . Slowly fill transmission with fluid until fluid overflows fill hole.

Transmission fluid, replacing

Fluid Capacity " Getrag transmission . . . . . . . . . . . 1 .0 liter (1 .1 US qts) " ZF transmission . . . . . . . . . . . . . 1 .2 liters (1 .3 US qts)

NOTEManual transmission fluid type should be printed on a label on the side of the transmission . If in doubt, consult an authorized BMW dealer for the up-to-date information on operating fluids.

6. Install and torque fluid fill plug .

Tightening Torque " Transmission drain or fill plug . . . . . . . 50 Nm (37 ft-Ib)

1 . Drive vehicle for a few miles to warm transmission . 2. Raise and safely support vehicle to access drain plug . WARNING " When raising the car uslng a floor jack or a hydraulic lift, carefully position the jack pad to prevent damaging the car body. A suitable liner (wood, rubber, etc .) should be placed between the jack and the car to prevent body damage . " Watch the jack closely. Make sure it stays stable and does not shíít or tilt. As the car is raised, the car may roll slightly and the jack may shift.

3. Place a drain pan under transmission and remove drain plug at bottom of transmission . See Fig . 1 .

TRANSMISSION SERVICE Back-up light switch, replacing 1 . Raise and safely support vehicle to access back-up light switch . NOTE" The back-up light switch on Getrag transmissions is in the left rear of the transmission . " The back-up light switch on ZF transmission is in the right front of the transmission.

2. Unscrew switch from transmission . 3. Install new switch . Tightening Torque " Back-up light switch to transmission . . . . . . . . . . . . . . . . . . 20 Nm (15 ft-ib) 4. Check transmission fluid leve¡ before lowering vehicle.

Fig. 1. Manual transmission fill (1) and drain plugs (2) .

TRANSMISSION SERVICE

MANUAL TRANSMISSION

230-3

Selector shaft seal, replacing (transmission instalied) 1 . Raise and safely support vehicle to access drain plug .

Seal

2. Support transmission with transmission jack .

Selector shaft

3. Remove driveshaft . See 260 Driveshaft . 4. Remove transmission crossmember and tilt down rear of transmission . CA UTION--

Tilting the engine to lower the transmission can lead to damage to various cgmponents due to lack of clearance . -On cars with AST (traction control) remove throttle body before tiltlng engine . -Remove brake fluid reservoir lf necessary.

5. Working at rear of selector shaft, disconnect shift linkage from selector shaft. See Fig. 2.

6542

Fig. 3. Selector shaft oil sea¡ being pried out with screwdriver.

Locking pin

Locking clip

0012020

Fig. 2. Disconnect shift linkage from transmission selector shaft by prying back locking clip and pushing locking pin out.

Fig. 4. Selector shaft seal being installed. 10 . Install driveshaft using new nuts. See 260 Driveshaft .

6. Carefully pry sea¡ out with a narrow seal remover or small screwdriver. See Fig. 3.

11 . Check transmission oil level, topping up as necessary.

7. Coat new seal with transmission fluid. Drive new seal in flush with housing . Use BMW special seal installation tool no. 23 2 260 or equivalent and a soft-faced (plastic) hammer . See Fig. 4.

Tightening Torques " Driveshaft to flex disc/ final drive flange . . . . . . . . . . . . . . See 260 Driveshaft " Transmission crossmember to chassis M8 . . . . . . . . . . . . . . . . . . . . . . 22-24 Nm (16-17 ft-1b) M10 . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 ft-Ib)

8. Reinstall shift linkage to selector shaft. 9. Fiaise transmission and reinstall crossmember.

TRANSMISSION SERVICE

230-4

MANUAL TRANSMISSION

Output shaft sea¡, replacing (transmission installed) 1 . Raise and safely support vehicle. Support transmission with transmission jack. WARNING " When raising the car using a floor jack or a hydraulic lift, carefully position the jack pad to prevent damaging the car body. A suitable liner (wood, rubber, etc.) should be placed between the jack and the car to prevent body damage. " Watch the jack closely. Make sure it stays stable and does not shift or tilt. As the car is raised, the car may roll slightly and the jack may shift.

2. Remove driveshaft. See 260 Driveshaft.

Fig. 6. Puller used to remove transmission seal .

3. Remove transmission crossmember and lower transmission at rear.

CAUTION-

Tilting the engine to lower the transmissíon can lead to damage to various componente due to lack of clearance . -On cars with AST (traction control) remove throttle body before tilting engine. -Remove brake fluid reservoir if necessary.

4. Bend back and remove collar nut lockplate. 5. Hold flange steady and remove collar lock nut (use 30mm thin-walled deep socket .) See Fig. 5.

Fig. 7. Output shaft seal being installed using seal driver (BMW special tool no . 23 2 300) . 9. Reinstall output flange (and shims, if applicable) to output shaft.

NOTE-

On Getrag S5D 200G and S5D 250G transmissions BMW recommends heating the output flange to about 176°F (80°C) to aid in installation . This can be done by placing the flange in hot water.

Fig. 5. Use holding tool when loosening output shaft collar nut. 6. Remove flange . If necessary, use a puller. 7. Use a sea¡ puller to remove seal from transmission housing. See Fig . 6. 8. Coat new sea¡ wíth transmission fluid and drive into position until it is flush with housing. See Fig. 7.

10 . Coat bearing surface of collar nut with sealer and install nut. Tighten collar nut in two stages. Insta¡¡ new lockplate. Bend tabs into flange grooves .

NOTE-

BMW recommends the use of a sealer such as Loctite® 242 when installing the flange collar nut to prevent oil from leaking past the threads.

TRANSMISSION SERVICE

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MANUAL TRANSMISSION

230-5

11 . Raise transmission and reinstall transmission crossmember. 12 . Install driveshaft using new nuts . See 260 Driveshaft . 13 . Check transmission oil leve¡, topping up as necessary. Tightening Torques " Transmission crossmember to chassis M8 . . . . . . . . . . . . . . . . . . . . . . 22-24 Nm (16-17 ft-Ib) M10 . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 ft-Ib) " Transmission output flange to output shaft Stage I . . . . . . . . . . . . . . . . . . . . . . 190 Nm (140 ft-Ib) Stage II (after loosening) . . . . . . . . . 120 Nm (89 ft-Ib)

Input shaft sea¡, replacing (transmission removed) Replacement of the input shaft sea¡ requires the removal of the transmission from the vehicle as described later in this repair group. 1 . Remove clutch release bearing and release lever from inside bellhousing . 2. Remove bolts for clutch release-bearing guide sleeve, noting bolt lengths. Remove sleeve and any spacers (shims) under ¡t . See Fig . 8.

001202 2Z:ZZZZ~ % _j

Fig . 9. Indent at oil seal housing (1). Punch holes in seal housing at indents and use sheet metal screw (2) to pul¡ sea¡ from transmission. NOTEUse care not to scratch or damage input shaft. Use a protective sleeve or tape the shaft when removing and installing the sea¡.

5. Lubricate new sea¡ with transmission oil and drive into place using BMW Special Tool no . 23 2 430 or equivalent . 6. Thoroughly clean guide sleeve mounting bolts, sealin surfaces, and threads in case . Apply sealer (Loctite 242 or equivalent) to guide sleeve sealing surface and bolts. Reinstall guide sleeve and spacer(s) . Tightening Torque " Guide sleeve to transmission M6xl2 bolt . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb)

TRANSMISSION REMOVAL AND INSTALLATION

0011640

Fig. 8. Clutch release bearing guide sleeve bolts. (Getrag transmission shown) . 3. With transmission on a workbench, remove input shaft sea¡ cover from inside bel¡-housing . 4. Locate two indents in seal housing. Use a punch or scribe to punch holes in housing at indents. Thread two sheet metal screws into holes and pulí seal out using screws . See Fig. 9.

Removal and installation of the transmission is best accomplished on a lift using a transmission jack. The engine must be supported from above using appropriate support equipment. This allows the engine to pivot on its mounts to access the upper Torx-head bolts at the bellhousing . WARNING " Make sure the car is stable and well supported at all times. Use a professional automotive lift or jack stands designed for the purpose . A floorjack is not adequate support. " The removal of the transmission may upset the balance of the vehicle on a líft.

TRANSMISSION REMOVAL AND INSTALLATION

230-6

MANUAL TRANSMISSION

Transmission, removing and installing CAUTION-

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

Shift console

Washers

1 . Disconnect negative (-) cable from battery.

Shift rod

0 0,

Shift rod retaining clip

2. Insta¡¡ engine support across engine bay. Raise engine so that weight of engine ís supported. See Fig. 10 .

0012024

Fig. 11 . Shift lever to transmission connection . 10. Unbolt clutch slave cylinder from side of transmission . Do not disconnect fluid hose . Suspend slave cylinder from chassis using stiff wire . CAUTION-

Do not operate clutch pedal with slave cylinder removed from transmission.

Fig. 10. Engine support equipment used to support engine from above before removing transmission .

11 . Support transmission from below with jack. Remove rear support crossmember from transmission . See Fig. 12 .

3. Raise vehicle to gain access to underside of car . 4. Support transmission with transmission jack . lf applicable, remove reinforcing cross brace from below engine/transmission . 5. Disconnect harness connector from reverse light switch on transmission . 6. Remove complete exhaust system and heat shield . See 180 Exhaust System . NOTE-

Disconnect oxygen sensor hamess connector(s) before lowering exhaust system.

7. Remove driveshaft . See 260 Driveshaft . 8. Disconnect shift rod from transmission selector shaft. See Fig. 11 . 9. Disconnect shift console from top of transmission . See 250 Gearshift Linkage.

TRANSMISSION REMOVAL AND INSTALLATION

Fig. 12 . Rear transmission crossmember (arrow).

0013135

12 . Lower transmission/engine assembly until it rests on front suspension crossmember. CAUTION-

Tilting the engine to lower the transmission can lead to damage to various componente due to lack of clearance at rear of engine -On cars with AST remove throttle body before tilting engine . -Remove brace fluid reservoir if necessary.

MANUAL TRANSMISSION

230-7

13 . Remove transmission mounting bolts (Torx-head) . Note length and location of bolts. See Fig. 13 .

Fig. 14 . Bellhousing alignment dowels (arrows) . 0611642

Fig. 13 . Transmission mounting bolts.

CAUTIONAt no time should the weight of the transmission be supportedby the transmission input shaft. 14. Remove transmission by pulling backward until the transmission input shaft clears the clutch disc splines, then pulí downwards. Lower jack and remove transmission . 15 . Installation is reverse of removal, keeping in mind the following: " When installing exchange transmission, transfer parts from old unit to exchange unit " Thoroughly clean input shaft and clutch disc splines. Lightly lubrícate transmission input shaft before installing . " Be sure bellhousing dowels are correctly located. See Fig. 14 . " Center rear of transmission in driveshaft tunnel before tightening transmission support bracket.

16 . Install driveshaft and preload center bearing bracket. Use new nuts when mounting driveshaft to transmissíon/flex disc and final drive. See 260 Driveshaft . 17 . Refill transmission with appropriate lubricant before starting or towing the car. See Transmission Fluid Service earlier in this repair group. Tightening Torques " Reinforcing cross brace to chassis (M10) . . . . . . . . . . . . . . . . . 42 Nm (31 ft-Ib) " Rubber mount to transmission or bracket nut (M8) . . . . . . . . . . . . . . . 21 Nm (16 ft-Ib) " Slave cylinder to transmission . . . . . . 22 Nm (16 ft-Ib) " Transmission crossmember to chassis M8 . . . . . . . . . . . . . . . . . . . . . . 22-24 Nm (16-17 ft-Ib) M10 . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 ft-Ib) Transmission to engine (Torx-head) " M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft-Ib) M10 . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Nm (32 ft-Ib) M12 . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Nm (53 ft-Ib) " Transmission drain/fill plugs . . . . . . . . 50 Nm (37 ft-Ib)

NOTE Washers should always be used with Torx-head bolts. Installing bolts without washers will make them difficult to loosen .

TRANSMISSION REMOVAL AND INSTALLATION

AUTOMATIC TRANSMISSION

240-1

240 Automatic Transmission GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240-1

TRANSMISSION REMOVAL AND INSTALLATION

TRANSMISSION SERVICE . . . . . . . . . . . . . 240-1

. . . . . . . . . . . . . . . . . . . . . . .240-4

Transmission, removing and installing . . . . . . .240-4

ATF leve¡, checking . . . . . . . . . . . . . . . . . . . . . 240-1 ATF, draining and filling . . . . . . . . . . . . . . . . . 240-2

TABLE a. Automatic Transmission Gear Ratios . . . . . . . . . . . 240-1

GENERAL

TRANSMISSION SERVICE

Automatic transmissions are identified by code letters found on a data plate located on the side of the transmission case, behind the manual valve lever. See 200 Transmission-General for application information . For gear ratio specifications, see Table a.

ATF leve¡, checking

The automatic transmissions installed in the E36 models are normally filled with Dexron III automatic transmission fluid (ATF), although alternative fluids have been installed from the factory, depending on transmission type and model year. Some transmíssions are filled with a special BMW "lifetime" automatic transmission fluid, which does not require periodic fluid changes.

CAUTIONATF does not circulate unless the engine is running. When towing an automafic transmission vehicle, use a flat-bed truck or ralse the rear wheels off the ground.

CAUTIONMixing different types of transmission fluids will lead to transmission failure.

The electronic transmission control module (TCM) monitors transmission operation for faults and alerts the driver by illuminating the transmission fault indicator on the instrument panel . On-board diagnostic codes stored in the TCM must be downloaded and interpreted by trained technicians using special BMW diagnostic equipment.

NOTEThe transmission lubricant instafed can be found on a type plate on the side of the transmission . In addition, a sticker may be located on the fluid sump indicating the type oftransmission lubricant used. Ifin doubt, con sult an authorized BMW dealer for altemate fluid use and current information regarding transmission operating fluids.

NOTEInternal repairs to the automatic transmission require special service equipment and knowledge . Ifit is determined that interna¡ service is required, consult en authorízedBMWdealerabouta factoryreconditioned unit or a transmission rebuild.

The transmission is not equipped with a dipstick . Checking the ATF leve¡ requires measuring and maintaining a specified ATF temperature during the checking procedure. The checking temperature is not fully warm or cold (the ATF sump should be approximately warm to the touch) .

Table a. Automatic Transmission Gear Ratios Transmission Gear ratios: 1 st 2nd 3rd 4th 5th Reverse

MS 310R (THM-R1)

MS 310R (THM-Rl)

MS 310Z (5HP 18)

2 .40 1 .47 1 .00 0 .72 2 .00

2 .86 1 .62 1 .00 0 .72 2 .00

3.67 2 .00 1 .41 1 .00 0 .74 4 .10

(1992-1993)

(1993-on)

MS 270R (THM-R1) 2 .86 1 .62 1 .00 0 .72 2 .00

TRANSMISSION SERVICE

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240-2

AUTOMATIC TRANSMISSION

WARNING -

If the appropriate temperature measuring equipment is not available, ATF leve¡ checking should be left to an authorized BMW dealer The checking procedure should be done on a lift with the engine running in neutral. In addition, the transmission fluid temperature must be maintained within a narrow range during the checking procedure.

1 . Place vehicle on a lift . WARNING -

To lift the vehicle safely, see 010 Fundamentals for

the Do-it-Yourself Owner.

0011742

2. Warm up drivetrain by running engine until ATF reaches specified temperature . Apply brake and, while idling engine, shift through all gears severa¡ times. Turn engine off. ATF Level Checking " Fluid temperature . . . . . . . . . . . . . 30-55°C (86-131°F) 3. Remove ATF fill plug . Place transmission in neutral and restart engine. See Fig. 1 or Fig. 2.

Fig. 2. ATF drain plug (A) and fill plug (B) on A5S 310Z transmission . Tightening Torques " ATF fill plug to ATF sump MS 270R/A4S 31 OR . . . . . . . . . . . . . 33 Nm (24 ft-Ib) MS 310Z (M30 plug) . . . . . . . . . . . . 100 Nm (74 ft-Ib)

ATF, draining and filling The procedure given here includes removal and installation of the ATF (luid strainer (filter) . 1 . Remove drain plug and drain fluid into container. See Fig. 3 or Fig. 2 given earlier.

0~ 0 /\1--Z.IZ

~~~ "o

15/

A 011743

Fig. 1. ATF fill plug (A) on MS 270 R/A4S 310R transmissions. 4. With ATF at specified temperature, add (luid until it spilis from fill hole . WARNING -

HotATFcan scald. Weareye protection and protective clothing and gloves during the check. If the transmission was overfilled, hot ATF will spill from the filler hole when the fill plug is removed.

5. Reinstall fill plug using new sealing ring .

TRANSMISSION SERVICE

0011595

Fig. 3. ATF drain plug (A) on A4S 270 R/A4S 310R . WARNING -

The ATF must not be hot when draining. Do not drain the ATF if the engine andlor transmission Is hot. Hot ATF can scald. Wear eye protection, protective clothing and gloves.

AUTOMATIC TRANSMISSION 2. On MS 270R/A4S 310R transmissions: Remove front and rear oil sump mounting bolts and remove sumps and sump gaskets. NOTEThe MS 270 R/A4S 310 R transmissions may be fitted with ASE (inch) bolts.

3. On A5S 310Z transmission : Remove oil sump mounting bolts and brackets, noting position of brackets . Remove sump and sump gasket . 4. Remove ATF otra¡ner mount¡ng screws and remove strainer together with gasket or O-ring . See Fig. 4 or Fig. 5.

240- 3

5. Installation is reverse of Rmoval .

" Always replace sea¡ for drain plug and al¡ gasket(s) and O-rings. " Clean sump and sump magnet(s) using a lint-free cloth. " On MS 270R/A4S 310R transmissions: Use new bolts at sump and tighten bolts in-line, one after other (do nottighten bolts in a cross-wise pattern) . " On MS 310Z transmission, be sure to instan rounded sump clamping brackets at corners of sump . " Fill transmission with approved fluid. " Check fluid level as described under ATF leve¡, checking . NOTEUse newsump bolts purchased from BMW. Alternatively, clean old bolts and coat with Loctite® thread locking compound or equivalent

Automatic Transmission Fluid Capacity (refill only) " MS 270R/A4S310R Removal of large sump only . . . . . . . . 3.0 liters (3 .2 qt) Removal of both sumps . . . . . . . . . . . 5.0 liters (5 .3 qt) " MS 310Z . . . . . . . . . . . . . . . . . . . . . . 3.3 liters (3 .5 qt)

Fig. 4. A4S 270R/A4S 310R fluid strainer mounting boits (arrows) .

Tightening Torques " ATF drain plug to ATF sump MS 270R/A4S 310R . . . . . . . . . . . . 25 Nm (18 ft-Ib) MS 310Z (M10 plug) . . . . . . . . . . . . 16 Nm (12 ft-Ib) " ATF fill plug to ATF sump MS 270R/A4S 310R . . . . . . . . . . . . 33 Nm (24 ft-Ib) MS 310Z (M30 plug) . . . . . . . . . : . 100 Nm (74 ft-Ib) " ATF strainer to valve body MS 270R/A4S 310R . . . . . . . . . . . . 20 Nm (15 ft-Ib) MS 310Z . . . . . . . . . . . . . . . . . . . . . . 6 Nm (53 in-lb) " ATF sump to transmission MS 270R/A4S 310R (M6) . . . . . . . . . 12 Nm (9 ft-¡b) MS 310Z (M6) . . . . . . . . . . . . . . . . . . 6 Nm (53 in-¡b)

0013230

Fig. 5. A5S 310Z fluid strainer mounting boits (arrows) .

TRANSMISSION SERVICE

240-4

AUTOMATIC TRANSMISSION

TRANSMISSION REMOVAL AND INSTALLATION Removal and installation of the transmission is best accomplished on a lift using a transmission jack. Use caution and safe workshop practices when working beneath car and lowering transmission . WARNING -

To lift the vehicle safely, see 010 Fundamentals for

the Do-it-Yourself Owner. CAUTION-

" Be sure the vehicle is properly supported. The removal of the transmission may upset the balance of the vehicle on a lift. " Tilting the engine to remove the transmission can lead to damage to various components due to lack of clearance . -On cars with AST remove throttle body. -Remove brake fluid reservoir if necessary.

Fig. 6. Engine support equipment used to support engine from above before removing transmission . 3. Raise vehicle to gain access to underside of car. 4. Drain ATF from transmission as described earlier.

Torx-head bolts are used to mount the transmission to the bellhousing . Be sure to have appropriate tools on hand before starting the job.

5. Disconnect oxygen sensor harness. Remove exhaust system, and exhaust heat shield . See 180 Exhaust System .

Transmission, removing and installing

6. Remove driveshaft . See 260 Driveshaft .

1 . Disconnect negative (-) cable from battery. CA UTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡.

7. With selector lever in Park, disconnect shift selector lever cable from lever and remove cable bracket . Hold linkage clamping bolt stationary when loosening clamping nut. See Fig. 7.

2. Install engine support across engine bay. Raise and safely support vehicle . See Fig. 6. WARNING -

" When raising the car using a floor jack or a hydraulic lift, carefully position the jack pad to prevent damaging the car body. A suitable liner (wood, rubber, etc.) should be placed between the jack and the car to prevent body damage . " Watch the jack closely. Make sure it stays stable and does not shift or tilt. As the car is raised, the car may roll slightty and the jack may shift.

CAUTION-

Removal of transmission will cause engine to tip unless engine support is used.

TRANSMISSION REMOVAL AND INSTALLATION

Fig. 7. Selector lever cable clamping nut (A). Loosen cable clamping nut (B) and remove cable from bracket. Always counterhold clamping bolt when loosening nut.

AUTOMATIC TRANSMISSION

240-5

8. Disconnect main harness connector from transmission by turning its bayonet lock ring counterclockwise . Remove wiring harness from transmission housing . See Fig. 8. A Bellhousing access hole Socket wrench

0012592

Fig. 9. Access and remove torque converter boits through hole in bellhousing cover. Fig. 8. Harness connector at automatic transmission .

fij

9. Where applicable, disconnect harness connector from speed sensor at top óf transmission . 10 . Disconnect transmission cooler line clamps from engine . Disconnect lines from transmission . 11 . Support transmission with transmission jack . Remove reinforcing cross brace (if applicable) and transmission support crossmember. NOTENote installation position of support crossmember.

12 . Remove access plug in cover plate on right side of engine block and remove torque converter bolts. Turn crankshaft to access boits. See Fig . 9. 13 . Remove bellhousing-to-engine mounting bolts. See Fig . 10 .

Fig. 10 . Transmission-to-engine Torx-head mounting bolts.

TRANSMISSION REMOVAL AND INSTALLATION

240-6

AUTOMATIC TRANSMISSION

14 . Remove transmission by pulling back and down . Lower jack to allow transmission to clear vehicle. CA UTION-

Do not allow the torque converter to fati off the transmission inputshaft.

15 . Installation is reverse of removal, noting the following: " Blowoutofcoolerlineswithlow-pressurecompressed air and flush cooler with clean ATF twice before reattaching lines to transmission . CAUTION-

" Wear safety glasses when working with compressedair. " Do not reuse ATF after flushing.

" Install new sealing washers on hollow bolts. " Insta¡¡ new O-rings on transmission cooler lines, where applicable. " Inspect drive plate for cracks or elongated holes. Replace if necessary. " Check to be sure torque converter is seated correctly in transmission during final installation . " When mounting transmission to engine, the three mounting tabs on torque converter must be aligned with indentations on driveplate . Use an alignment dowel to line up bolt holes, if necessary. " Fill transmission with clean ATF until oil leve¡ is even with fill hole. Then check fluid leve¡ as described earlier. " Adjust gearshift mechanism. See 250 Gearshift linkage.

Tightening Torques " ATF drain plug to ATF sump MS 270R/A4S 310R . . . . . . . . . . . . . 25 Nm (18 ft-Ib) ASS 310Z (M10 plug) . . . . . . . . . . . . . 16 Nm (12 ft-Ib) " ATF fill plug to ATF sump MS 270R/A4S 310R . . . . . . . . . . . . . 33 Nm (24 ft-Ib) MS 310Z (M30 plug) . . . . . . . . . . . . 100 Nm (74 ft-Ib) " ATF cooler lines (A4S 270R/A4S 310R) Coupling nuts . . . . . . . . . . . . . . . . . . . 20 Nm (15 ft-Ib) Hollow bolts . . . . . . . . . . . . . . . . . . . . 37 Nm (28 ft-Ib) " Reinforcing cross brace to chassis (M10) . . . . . . . . . . . . . . . . . 42 Nm (31 ft-Ib) " Torque converter to drive plate (M10) . . . . . . . . . . . . . . 45 Nm (33 ft-Ib) " Transmission support crossmember to chassis M8 . . . . . . . . . . . . . . . . . . . . . . 22-24 Nm (16-17 ft-1b) M10 . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 ft-Ib) Transmissíon to engine (Torx-head with washer) " M8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Nm (15 ft-Ib) M10 . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 ft-Ib) M12 . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Nm (53ft-Ib)

NOTE-

Torx-head mounting bolts should always be used with washers to prevent difficult removal.

TRANSMISSION REMOVAL AND INSTALLATION

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GEARSHIFT LINKAGE

250-1

250 Gearshift Linkage GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250-1 MANUAL TRANSMISSION GEARSHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . 250-1

Gearshift lever, removing (manual transmission) . . . . . . . . . . . . . . . . . 250-1 Gearshift lever, installing (manual transmission) . . . . . . . . . . . . . . . . . 250-2

AUTOMATIC TRANSMISSION

GEARSHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 250-3 Gearshift mechanism, adjusting (automatic transmission) . . . . . . . . . . . . . . . . 250-3 Gear position/neutral safety switch, replacing (automatic transmission) . . . . . . . . . . . . . . . . 250-4 Automatic shiftlock, checking function (automatic transmission) . . . . . . . . . . . . . . . . 250-5 Shift interlock, checking function (automatic transmission) . . . . . . . . . . . . . . . .250-6

GENERAL This repair group covers transmission gearshift and linkage service. Special service tools are required for some of the procedures given here . To gain access to the complete gearshift mechanism ít is necessary to remove the exhaust system and the driveshaft as described in 180 Exhaust System and 260 Driveshaft.

MANUAL TRANSMISSION GEARSHIFT

Gearshift lever, removing (manual transmission) The manual transmission gearshift linkage is shown in Fig. 1 . Use this illustration as a guide when removing and installing the linkage. 1 . Pull straight up on shift knob lo remove it from shift lever. NOTE Removal of the shift knob will require about 90 lbs . of force.

2. Pry up on rear of shift boot to unclip, then remove boot from front retainers. 3. Raise vehicle to gain access to underside of vehicle. WARNING Make sure the car is stable and well supported at afl times . Use a professional automotive lift or jack stands designed for the purpose. A floor jack is not adequate support.

Fig. 1 . Manual transmission gearshift linkage. 4. Disconnect oxygen sensor harness connectors . Remove complete exhaust system . See 180 Exhaust System .

MANUAL TRANSMISSION GEARSHIFT

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250-2

GEARSHIFT LINKAGE

5. Remove driveshaft. See 260 Driveshaft . 6. Support transmission with transmission jack. Remove crossmember from rear of transmission . See Fig. 2.

9. Release gearshift lever retaining ring from below by turning special tool 90° ( 1/4 turn) counterclockwise . See Fig. 4.

BMW Tool No . 25 1 110 or equivalent

6532 0013135

Fig . 2. Rear transmission crossmember (arrow) .

7. Lower rear of transmission to access gearshift linkage. CAUTION-

Tilting the engine to lower the transmission can lead to damage to various componente due to lack of clearance . -On cars with AST remove throttle body. -Remove brake fluid reservoir if necessary.

8. Working below transmission, disconnect shift rod from gearshift lever. Note washers on either side of shift rod end. See Fig. 3.

Fig . 4 .

Shift lever retaining ring being removed using BMW special tool 25 1 110 .

10 . Raise transmission and temporarily instan transmission crossmember. 11 . Lower vehicle. Working from inside passenger compartment, pull up on gearshift lever to remove it together with retaining ring and rubber grommet.

Gearshift lever, installing (manual transmission) 1 . Instan shift lever, aligning locking tabs with openings in shift console. Press down on retaining ring until it clicks into place. See Fig. 5.

\ Retaining clip

Shift rod

Fig . 3 . Pull off shift rod retaining clip in direction of arrow (t) ; disengage shift rod from gearshift lever (2) .

MANUAL TRANSMISSION GEARSHIFT

Fig. 5. Shift lever retaining ring . Fit plastic tabs into slots of shift console (arrows) .

GEARSHIFT LINKAGE 2. Install rubber grommet with arrow pointing forward. Install shift rod and shift boot . NOTE-

Install rubbergrommet correctly so that is seals out water.

3. Connect shift rod to shift lever. Install transmission crossmember. Lift transmission and tighten crossmember bolts.

AUTOMATic TRANSMISSION GEARSHIFT The automatic transmission shift mechanism is shown in Fig. 6. Use the illustration as a guide when servícing the gearshift mechanism, including shift cable replacement.

Gearshift mechanism, adjusting (automatic transmission) 1 . Position selector lever in Park.

NOTE-

Before connecting the shift rod to the lever, be sure the gearshift leven is facing the correct way as illustrated in Fig. 1 .

4. Install driveshaft and heat shield . See 260 Driveshaft . 5. Reinstall exhaust system . See 180 Exhaust System . Connect oxygen sensor harness connectors . 6. Lower vehicle. Insta¡¡ shift boot cover. Push shift knob onto lever. Tightening Torques " Driveshaft to final drive flange (with U-joint) . . . . . . . . . . . See 250 Driveshaft " Flex-disc to driveshaft or transmission flange . . . . . . . . . . . See 250 Driveshaft " Transmission crossmember to body (M8) . . . . . . . . . . . . . . . . . . . . 21 Nm (16 ft-Ib)

Shift cable

2. Raise vehicle to gain access to shift linkage. WARNING Make sure the can is stable and well supported at all times . Use a professional automotive lift or jack stands designed for the purpose.

3. Loosen selector cable clamping nut. See Fig. 7. 4. Push shift lever forward toward engine (Park position) while applying light pressure on cable end. Tighten cable clamping nut. NOTE-

Do not overtighten the nut so that it twists the cable.

Tightening Torque " Shift cable clamping nut . . . . . . . 10-12 Nm (75-9 ft-Ib)

r\1 /S1

Manual valve leven (at transmission)

250-3

Gear position/ neutral safety switch

Automatic shilo solenoid id

Fig. 6. Automatic transmission gearshift assembfy. AUTOMATIC TRANSMISSION GEARSHIFT

250- 4

GEARSHIFT LINKAGE

r% ; 5 (((((C

"~;

Fig . 7. Selector lever cable clamping nut (A) . Counterhold clamping bolt when loosening nut .

Gear position/neutral safety switch, replacing (automatic transmission) NOTEThe gear-positionlneutral safety switch is also sometimes referred to as the automatic transmission range switch . Failure of the gear positionlneutral safety switch can cause a no-start condition . In acidition, since it signals gearshift position to the transmission control unit, a faulty switch can cause erratic transmission operation .

Fig. 8. Disconnect harness connector to gear position/neutral safety switch by pressing connector retaining clips together (arrows) . Switch mounting screws shown at 1 .

1 . Remove hex-head screw (3mm allen key) from shift lever handle and remove handle . Carefully pry up cover from gearshift lever console . 2 . Disconnect harness connector from gear positionlneutral safety switch and remove mounting screws . See Fig . 8 . 3. Remove gear positionlneutral safety switch by moving selector until pin on lever aligns with slot on switch . Pull switch straight up and off . See Fig . 9 . 4. Installation is reverse of removal, noting the following : " Before installing switch, align plastic contact slide inside switch with slot in switch . See Fig . 10 . " Instan switch so that contact slide on switch aligns with slot on switch . Then position gearshift lever pin to slot on switch and install switch . " When installing shift lever handle, engage pín on re lease button to hole in pulí rod . See Fig . 11 .

Tightening Torques " Console to body . . . . . . . . . . . . . . . . . . 7 Nm (62 in-lb) " Gear positionlneutral safety switch to shift console . . . . . . . . . . . . . . . . . . 4 .5 Nm (40 in-lb)

AUTOMATIC TRANSMISSION GEARSHIFT

Fig . 9 .

Contact slide in switch aligns to slot on switch and pin on lever.

GEARSHIFT LINKAGE

250- 5

Fig . 10 . Align contact slide (1) with slot in switch housing (2) before installing gear position/neutral safety switch .

Fig. 12 . Automatic shiftlock prevents drive gear selection until the brake pedal is depressed . 4 . Check that selector lever can now be moved out of P or N . NOTE The next test should be performed in an open area with the parking brake on and with extreme caution.

Fig . 11 . Engage release button pin to hole in pull rod before installing shift lever handle .

Automatic shiftiock, checking function (automatic transmission) The automatic shiftlock uses an electríc solenoid to lock the selector lever in P or N . Depressing the foot brake with the ignition on energizes the solenoid, allowing the lever to be moved into a drive gear. The solenoid is energized only when the engine speed is below 2,500 rpm and the vehicle speed is below 3 mph . The solenoid ís mounted in the right-hand side of the selector lever housing. See Fig . 12 .

5 . With selector lever in P or N and brake pedal depressed, raise engine above 2,500 rpm . Check that selector lever cannot be moved out of P or N . If any faults are found check the electrical operation of the shiftlock solenoid and check for wiring faults to or from the transmission control module (TCM) . See 610 Electrical Component Locations and Electrical Wiring Diagrams . NOTE The solenoid is controlled via the TCM, using brake pedal position, engine speed, and road speed as controlling inputs.

1 . With engine running and car stopped, place selector lever in P or N . 2 . Without depressing brake pedal, check that selector lever is locked in position P or N . 3 . Depress brake pedal firmly. Solenoid should be heard to energize .

AUTOMATIC TRANSMISSION GEARSHIFT

250-6

GEARSHIFT LINKAGE 1 . Shift selector lever to park (P) position and turn ignition key to the "zero" (off) position .

Shift interlock, checking function (automatic transmission) The shift interlock uses a cable between the ignition switch and the shift lever to lock the shift lever in the park position when the key is in the off position or removed . This feature also prevents the key from being removed from the ignition lock until the selector lever is in P. Fig . 13 .

2. Remove ignition key. Check that selector lever cannot be shifted out of P position . NOTE" lt must only be possible to remove ignition key with selector lever in P position. " Shift interlock cable must not be kinked.

3. Turn ignition key on and depress brake pedal. Check that selector lever moves freely from gear to gear. 4. With the selector lever in a gear position other than P, attempt to move the key to the zero position . The key should not go into the zero position . If any faults are found check the cable for kinks and the cable attachment points for damage or faults.

Latchirig Gate

0012714

Fig. 13 . Shift interlock serves two safety functions: 1) it locks shift lever in park (P) when the key is removed, and 2) it prevents removal of key until shift lever is moved into P.

AUTOMATIC TRANSMISSION GEARSHIFT

DRIVESHAFT

260-1

260 Driveshaft GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260-1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 260-1 DRIVESHAFT SERVICE . . . . . . . . . . . . . . . .260-3

Driveshaft, aligning . . . . . . . . . . . . . . . . . . . . . 260-3 Driveshaft, removing . . . . . . . . . . . . . . . . . . . . 260-4

Driveshaft, installing . . . . . . . . . . . . . . . . . . . . . 260-4 Flex-disc, replacing . . . . . . . . . . . . . . . . . . . . . 260-5 Center bearing assembly, replacing . . . . . . . .260-6 Front centering guide, replacing . . . . . . . . . . . 260-7 TABLE a. Driveshaft Troubleshooting. . . . . . . . . . . . . . . . . . . . 260-2

GENERAL

NOTE-

The two-piece driveshaft is joined in the center by a sliding splined coupling . This coupling compensates for fore and aft movement of the drive line . The driveshaft ís connected to the transmission by a rubber flex-disc and to the final drive by a universal joint. It is supported in the micidle by a center support bearing. The bearing is mounted in rubber to isolate vibration. See Fig. 1 .

Suspension .

TROU BLESHOOTING The source of driveline vibrations and noise can be difficult to pinpoint . Engine, transmission, rear axle, or wheel vibrations can be transmitted through the driveshaft to the car body. Noises from the rear of the car may be caused by final drive problems, or by faulty wheel bearings, drive axies, or even worn or improperly inflated tires .

For rear drive axle repair information, see 330 Rear

Driveshaft noise or vibration may be caused by worn or damaged components . Check the universal joints for play . With the driveshaft installed, pull and twist the driveshaft while watching the joint . The BMW specification for play is very small, so almost any noticeable play could indicate a problem. Check the torque of the fasteners at the flange connections . Check the rubber of the flex-disc and center bearing for dete rioration or tearíng and check for preload at the center bearing with a visual inspection . Check the driveshaft for broken or missing balance weights . The weights are welded tabs on the driveshaft tubes. In addition to inspecting for faulty driveshaft parts, the installed angles of the driveshaft should also be considered .

Rear section Splined shaft of driveshaft Center support ` Clamping sleeve bearíng assembly

Center universal joint Flex-disc

Differential input flange 0013110

Fig. 1 . Driveshaft and final drive assembly .

TROUBLESHOOTING

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260-2

DRIVESHAFT

Further inspection requires removal of the driveshaft . Check the front centering guide on the transmission output flange for damage or misalignment . Also check runout at the transmission output flange and output shaft, and at the final drive input flange. Check the bolt hole bores in the flange for wear and elongation .

NOTEWith the driveshaft installed, the actual amount that the universal joints pivot is limited. For the most accurate test, check universal joints in their normal range of movement. If inspection reveals nothing wrong with the driveshaft, it may need to be rebalanced. This can be done by a speciality driveshaft repair shop. Also, check the alignment of the driveshaft as described below.

Driveshaft flange runout (max. allowable) " Transmission output flange axial play . . . . . . . . . . . . . . . . . . . 0.10 mm (0.004 in.) radial play . . . . . . . . . . . . . . . . . . . 0.07 mm (0.003 in.) " Final drive input flange radial play (measured at driveshaft centering lip) . . . . . . . . 0.07 mm (0.003 in .)

NOTEMinor driveshaft vibrations can often be corrected simply by disconnecting the driveshaft at the final drive, and repositíoning the driveshaft 90°, 180° or270° in relation to the final drive input flange.

Spin the center bearing and check for the smooth operation without play. Check that the splines of the sliding coupling move freely. Clean and lubricate the splines with molybdenum disulfide grease (Molykote® Longterm 2 or equivalent) .

Table a lists symptoms of driveshaft problems and their probable causes . Most of the repair information is contained within this repair group.

Check the universal joints for wearor binding . If any joint is difficult to move or binds, the driveshaft section should be replaced.

Table a. Driveshaft Troubleshooting

Symptom

Probable cause

Corrective action

1 . Vibration when starting off (forward or reverse).

a. Incorrect preload of center bearing . b. Center bearing rubber deteriorated. c . Flex-disc damaged or worn. d. Engine or transmission mounts faulty.

a. Check preload of center bearing . Readjust preload . See Fig . 6. b. Inspect center bearing and rubber. Replace if necessary. c. Inspect flex-disc. Replace if necessary. d. Inspect engine and transmission mounts. Align or replace, if necessary. e. Check front centering guide and replace if necessary. Check runout of driveshaft flanges .

e. Front centering guide worn, or driveshaft mounting flanges out of round. f. Universal joints worn or seized . g. Sliding coupling seized . h. Driveshaft misaligned . 2. Noise during on/off throttle or when engagíng clutch .

a. Final drive components worn or damaged (excessive pinion-to-ringgear clearance) . b. Drive axle or CV joint faulty. c. Sliding coupling seized .

3. Vibration at 25 to 30 mph (40 to 50 km/h) .

a. Front centering guide worn, or driveshaft mounting flanges out of round or damaged . b. Universal joints worn or seized . c. Flex-disc damaged or worn. d. Center bearing rubber deteriorated . e. Sliding coupling seized . f. Misaligned installed position.

f. Check universal joint play and movement. Replace driveshaft if necessary. g . Remove driveshaft and check movement of sliding coupling . Clean coupling splines and replace parts as necessary. h . Check driveshaft alignment . a. Remove final drive and repair. b. Inspect drive axles and CV joints . Repair or replace as necessary. c. Remove driveshaft and check movement of sliding coupling . Clean coupling splines and replace parts as necessary. a. Check front centering guide and replace if necessary. Check runout of driveshaft mounting flanges. b. Check universal joint play and movement . Replace driveshaft if necessary. c. Inspect flex-disc . Replace if necessary. d. Inspect center bearing . Replace if necessary. e. Remove driveshaft and check movement of sliding coupling . Clean coupling splines and replace parts as necessary. f. Check driveshaft alignment.

TROUBLESHOOTING

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DRIVESHAFT

260-3

Table a. Driveshaft Troubleshooting (continued) Symptom 4 . Vibration, audible rumble over 35 mph (60 km/h) .

Probable cause

Corrective action

a . Front centering guide worn, or driveshaft mounting flanges out of round or damaged . b. Mounting flange bolts loose or holes worn . c . Driveshaft unbalanced .

a . Check front centering guide and replace if necessary. Check runout of driveshaft mounting flanges . b . Remove driveshaft and check transmission output flange and final drive input flange . Replace if necessary. c . Check driveshaft for loose or missing balance weights . Have driveshaft rebalanced or replace if necessary. d . Check universal joint play and movement . Replace driveshaft if necessary.

d . Universal joints worn or seized . e . Sliding coupling seized . 1 f. g. h. i.

Incorrect preload of center bearing . Center bearing faulty. Final drive rubber mount faulty Driveshaft misaligned .

e . Remove driveshaft and check movement of sliding coupling . Clean coupling splines or replace parts as necessary. f. g. h. i.

Check preload of center bearing . Readjust if necessary. Replace center bearing . Inspect final drive rubber mount and replace if necessary. Check driveshaft alignment.

DRIVESHAFT SERVICE Repair kits for the universal joints are not available, and it is not common practice to repair the universal joints on BMW driveshafts . Worn or damaged universal joints usually require replacement of that section of the driveshaft . The driveshaft is balanced to cose tolerances . Whenever it is to be removed or disassembied, the mounting flanges and driveshaft sections should be marked with paint or a punch before proceeding with work. This will ensure that the driveshaft can be reassembled or installed in exactly the same orientation .

Universal joint play " Maximum allowable . . . . . . . . . . . 0 .15 mm (0 .006 in .)

Driveshaft, aligning The alignment of the driveshaft does not normally need to be checked unless the engine/transmission or the final drive have been removed and installed . If, however, all other parts of the driveshaft have been inspected and found to be okay, but there is still noise or vibration, driveshaft alignment should be checked . There are two important driveshaft alignment checks . The first is to make sure that the driveshaft runs straight from the transmission to the final drive ; without any variation from sideto-side caused by misalignment of the engine/transmission in its mounts . Make a basic check by sighting along the driveshaft from back lo front . Any misalignment should be apparent from the center bearing forward . To adjust the side-to-side alignment, loosen the transmission or engine mounts to reposition them, then retighten the mounts : The driveshaft should be exactly centered in the driveshaft tunnel . See Fig . 2 .

Fig . 2 .

b:izó

Driveshaft side-to-side alignment . Driveshaft should be centered in driveshaft tunnel .

The second important driveshaft alignment check is more complicated . It checks the amount the driveshaft is angled vertically at the joints . This angle is known as driveshaft deflection . In general, there should be little deflection in the driveshaft between the engine, the center bearing, and the final drive. Precise checks require the use of a large protractor or some other means of measuring the angle of the engine and the final drive and comparing these angles to the angle of the driveshaft sections . To change the deflection angle, shims can be placed between the center bearing and the body or between the transmission and íts rear support. When using shims to change a deflection angle, keep in mind that the angle of adjacent joints will also change . Deflection angles should be as small as possible . DRIVESHAFT SERVICE

260- 4

DRIVESHAFT

CAUTION-

The maximum allowable change in height of the center bearing or transmission support using shims is 3 mm (0.12 in.).

Driveshaft, removing WARNING " Be sure the wheels are off the ground before removing the driveshaft. Set the parking brake before removing the driveshaft. " Once the driveshaft has been removed, the vehicle can roll regardless of whether the transmission is in gear or not.

0012037

" The driveshaft fs mounted to the transmission and final drive with self-locking nuts. These nuts are designed to be used only once and should be replaced during reassembly.

Fig. 4. Threaded clamping sleeve nut being loosened .

1 . Disconnect oxygen sensor electrical connectors and remove complete exhaust system . See 180 Exhaust System . 2. Remove exhaust heat shield and heat shield crossmember. 3. Matchmark front and rear driveshaft connections at transmissíon and final drive. 4. Remove driveshaft mounting bolts. See Fig. 3. Discard old nuts .

6. Support driveshaft and remove center support bearing mounting bolts. 7. Remove driveshaft but do not separate two halves . Pull down on center of driveshaft to facilitate removal. NOTE-

If driveshaft halves were separate and not matchmarked, assemble driveshaft as shown in drawing . If a vibration occurs, disassemble driveshaftand rotate one section 180°. See Fig. 5.

Fig. 5. Driveshaft alignment . Centerlines of universal joints (arrows) must be parallel or at 90° to each other

Driveshaft, installing 1 . Align driveshaft matchmarks at final drive and then at transmission flange . Start attaching nuts . Use new selflocking nuts . JG

Fig. 3. Front driveshaft to transmission mounting bolt being removed. Note open-end wrench (arrow) being used to counterhold bolt . 5. Loosen threaded clamping sleeve on driveshaft a few tucos. See Fig. 4.

DRIVESHAFT SERVICE

2. Position center support bearing and start attaching nuts . Use new self-locking nuts . 3. Tighten flange nuts while preventing bolts from twisting in coupling . Tighten final drive flange first, then tighten coupling at transmission . 4. Preload center support bearing by pushing bearing forward 4-6 mm (0 .16-0 .24 in .) from center . See Fig. 6. Tighten attaching bolts.

DRIVESHAFT

260-5

NOTEBolt grade is marked on the bolt head. When replacing bolts, only use bolts of the same strength and hardness as the originals installed.

Flex-disc, replacing The flex-disc between the front section of the driveshaft and the output flange of the transmission should be checked for cracks, tears, missing pieces, or distortion . Check for worn bolt hole bores in the flange . 1 . Remove driveshaft as described in Driveshaft, removing .

Fig. 6. Preload center bearing toward front 4-6 mm (arrow) .

5331

5 . Tightenthreadedsleeveondriveshafttopropertorque . 6 . Insta¡¡ heat shield and heat shield crossmember. 7 . Install exhaust system . See 180 Exhaust System . Connect wiring harness to oxygen sensors . 8 . Road test vehicle to check for noise or vibration . WARNING " Do not reuse self-locking nuts . These nuts are designed to be used only once . " Avóid stressing the flex-disc when torquing the bolts . Do this uy holding the bolts steady and turning the nuts on the flange side .

NOTE¡t is possible to only partially remove the driveshaft, leaving it connected to the final drive . The driveshaft can be tilted down in the center and slid off the transmission flange once the clamping sleeve is loosened and the center bearing bracket is unbolted. Suspend the driveshaft using stiff wire in as close to the installed position as possible. If the driveshaft hangs unsupported, the rear universal joint may be damaged. 2 . Unbolt flex-dísc from driveshaft . NOTERemovaland installation of the boltsmaybe made easier by placing a large hose clamp around the flex-disc, and tightening the clamp slightly to compress the cou pling. 3 . Insta¡¡ new flex-disc using new self-locking nuts . Molded arrows on coupling should face flange arms . See Fig . 7 .

Tightening Torques " Driveshaft center mount to body . . . . 21 Nm (16 ft-Ib) " Driveshaft clamping sleeve . . . . . . . . 10 Nm (89 in-lb) " Driveshaft to final drive flange With CV joint (M8) . . . . . . . . . . . . . . . 32 Nm (23 ft-Ib) Wth U-joint (M10 ribbed nut) . . . . . . . 80 Nm (59 ft-Ib) With U-joint (M10 compressed nut) . . 60 Nm (44 ft-Ib) " Flex-disc to driveshaft or transmission flange M10 (8 .8 grade) . . . . . . . . . . . . . . . . . 48 Nm (35 ft-Ib) M10 (10 .9 grade) . . . . . . . . . . . . . . . . 64 Nm (47 ft-Ib) M12 (8 .8 grade) . . . . . . . . . . . . . . . . . 81 Nm (60 ft-Ib) M12 (10 .9 grade) . . . . . . . . . . . . . . . 100 Nm (74 ft-Ib) M12 (10 .9 grade) (M3 models) . . . . . 115 Nm (85 ft-Ib) " Transmission crossmember to body (M8) . . . . . . . . . . . . . . . . . . . . 21 Nm (16 ft-Ib)

5:132

Fig . 7. When attaching flex-disc, molded arrows must point toward flange arms . DRIVESHAFT SERVICE

260-6

DRIVESHAFT

4. Insta¡¡ driveshaft as described in Driveshaft, installing. NOTE Torque only the nuts while holding the bolt heads. Thís will prevent damaging or fatiguing the rubber.

Tightening Torques " Driveshaft center mount to body . . . . 21 Nm (16 ft-Ib) " Driveshaft clamping sleeve . . . . . . . . 10 Nm (89 in-lb) " Driveshaft to final drive flange With CV joint (M8) . . . . . . . . . . . . . . . 32 Nm (23 ft-Ib) Wth U-joint (M10 ribbed nut) . . . . . . . 80 Nm (59 ft-Ib) With U-joint (M10 compressed nut) . . 60 Nm (44 ft-Ib) " Flex-disc to driveshaft or transmission flange M10 (8 .8 grade) . . . . . . . . . . . . . . . . . 48 Nm (35 ft-Ib) M10 (10.9 grade . . . . . . . . . . . . . . . . . 64 Nm (47 ft-Ib) M12 (8 .8 grade) . . . . . . . . . . . . . . . . . 81 Nm (60 ft-Ib) M12 (10.9 grade) . . . . . . . . . . . . . . . 100 Nm (74 ft-Ib) M12 (10.9 grade) (M3 models). . . . . 115 Nm (85 ft-Ib) " Transmission crossmember to body (M8) . . . . . . . . . . . . . . . . . . . . 21 Nm (16 ft-Ib)

5333

Fig. 9. Before pulling apart driveshaft sections, make matching marks as shown. 4. Inspect condition of rubber bushing for splined coupling . Replace worn or damaged parts. 5 . Remove center bearing circlip and dust guard. See Fig. 10 . Remove bearing from driveshaft using puller .

Center bearing assembly, replacing To replace the center bearing assembly, the driveshaft must be removed from the car. The center bearing assembly consists of a grooved ball bearing in a rubber mount. The bearing assembly is pressed onto the front section of the driveshaft and secured by a circlip. See Fig. 8 .

Dust cap Circlip

0012594

Fig. 8. Exploded view of driveshaft support bearing assembly. 1 . Remove driveshaft . See Driveshaft, removing . 2. Make matching marks on front and rear driveshaft sections . See Fig. 9. 3. Loosen clamping sleeve fully and pull driveshaft sections apart. Remove rubber bushing, washer, and clamping sleeve from front section.

DRIVESHAFT SERVICE

5334

Fig. 10. Center bearing circlip (arrow) to be removed. Driveshafl shown installed. NOTEInstall puller so that it pulls on inner hub of bearing . Pulling on outer ring of mount may tear rubber, and en tire bearing assembly will need to be replaced.

®RIVESHAFT 6. Before installation, make sure dust guard is on driveshaft, and then press center mount onto driveshaft flush with dust guard. 7. Place clamping sleeve, washer, and rubber bushing on front driveshaft section . Lubricate splines with molybdenum disulfide grease (Molykote0 Longterm 2 or equivalent) and then reassemble driveshaft .

NOTE-

Do not retighten clamping sleeve until driveshaft is installed.

8. Insta¡¡ dríveshaft. See Driveshaft, installing . 9. Tighten clamping sleeve . Tightening Torque " Clamping sleeve . . . . . . . . . . . . . . . . . 10 Nm (7.5 ft-Ib)

260-7

2. Pack cavity behind centering guide with heavy grease until grease is flush with bottom edge of guide. 3. Insert 14 mm (approximately %z in .) diameter mandrel or metal rod finto guide. Strike guide with hammer to force centering guide out.

NOTE-

The mandrel should fit snugly in the centering guide so that the grease cannot escape around the sides of the mandrel.

4. Remove old grease from driveshaft, lubricate new cen tering guide with molybdenum disulfide grease (Molykote ® Longterm 2 or equivalent) and drive it finto driveshaft .

NOTE-

The sealing lip of the guide should face outward and it should be driven into the driveshaft to a specified depth . See Fig . 11 .

Front centering guide, replacing The front centering guide centers the driveshaft in relation to the transmission . The guide is press-fit finto a cavity in the front of the driveshaft and slides onto the transmission output shaft. No specifications are given for wear of the guide, but generally the guide should fit snugly on the transmission output shaft.

NOTE-

Some driveshafts have a dust cap installed on the end of the driveshaft, over the centering guide. The dust cap may become bent or distorted when the driveshaft is removed or installed. Damage to the dust cap should not affect the centering guide and should not be mistaken for guide wear.

1 . Remove driveshaft . See Driveshaft, removing .

~) I~

4.5 mm (.177") B313

Fig. 11 . When installing new driveshaft centering guide, drive guide in until its protrusion depth is as shown. 5. Install driveshaft . See Driveshaft, installing .

DRIVESHAFT SERVICE

SUSPENSION, STEERING AND BRAKES-GENERAL

300-1

300 Suspension, Steering and Brakes-General GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .300-1

Front Suspension . . . . . . . . . . . . . . . . . . . . . . 300-1 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-2 Rear Suspension . . . . . . . . . . . . . . . . . . . . . . 300-2 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-2 Tires and wheeis . . . . . . . . . . . . . . . . . . . . . . . 300-2

M3 SUSPENSION AND BRAKES . . . . . . . . . . . 300-7 SUSPENSION AND STEERING

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 300-7

INTEGRATED SYSTEMS . . . . . . . . . . . . . . . 300-2

TABLE a. AST Indicator Lamp Function . . . . . . . . . . . . . . . . . 300-5 b. Suspension and Steering Troubleshooting . . . . . . .300-8

GENERAL

Front Suspension

This section covers general information for front and rear suspension, the steering system, and the brakíng and traction control systems.

The lower control arms connect the front suspension struts to mounting points on the subframe crossmember and the body . See Fig. 2 .

The BMW E36 suspension and steering systems are engineered to provide a compromise between taut, responsive handling and ride comfort. Although the front and rear suspension assemblies are independent subsystems, they work together to achieve BMW's overall combination of precise handling and comfort. See Fig . 1 .

Each front strut assembly includes a shock absorber cartridge inside the tubular strut housing and a large coil spring . The upper strut mount bearing allows the strut to turn with the wheels . The lower end of the strut, which includes the stub axle for the front wheel, connects to a ball-joint on the control arm.

Antilock Brake System (ABS) . . . . . . . . . . . . . 300-2 Al¡ Season Traction (AST) . . . . . . . . . . . . . . . 300-4

Fig. 1 . BMW E36 front and rear suspension systems.

0013098

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

300-2

SUSPENSION, STEERING AND BRAKES-GENERAL Rear Suspension The rear axle carrier is the main mounting point for the final drive housing and the rear suspension components . Trailing arms locatethe rear wheels and anchorthe springs, shocks and stabilizer bar. Drive axies with constant-velocity (CV) joints at both ends transfer power from the differential to the road wheels . The differential is mounted to the rear axle carrier through rubber mounts and bushings to hele isolate drivetrain noise and vibration.

Brakes E36 cars are equipped with power disc brakes with an integral antilock brakes (ABS) . The parking brake is a dual-drum system integrated with the rear brake rotors . See Fig. 3. Power assist is provided by a vacuum booster when the engine is running. The brake pedal pushrod is connected directly to the master cylinder, so failure of the vacuum booster does not normally result in total brake failure. Fig. 2. Front suspension control arm (arrow).

0012124

The front suspension is designed with minimum positive steering offset . This geometry contributes to stability when traction is unequal from side to side . Suspension travel is limited by rubber bump stops. The three point mounting of each L-shaped control arm erecisely controls thefront-to-rear and side-to-side position of the strut, while the flexibility of the joints and mounts also allows the movement necessary for suspension travel . The control arm mounting points are designed with anti-dive geometry . The suspension reduces the normal tendency for the front of the vehicle to dive under hard braking. Control arm position is fixed, with no adjustment provisions on the control arms for alter¡ng front wheel al ignment. A stabilizer bar mounted to both control arms heles to reduce body rol¡ whencomering .

Steering The variable-assist power steering system consists of an engine-driven hydraulic pump, a rack-and-pinion type steering gear, and connecting linkage to the road wheels . The E36 utilizes an engine-speed dependent variable effort steering system . At low speeds, maximum power assist is provided to ease parking and city driving . At high speeds, assist is reduced to ensure stability. The steering linkage connects the rack-and-pinion unit through tie rods to the steering arms . The tie rod ends allow the wheels to pivot and react to suspension travel .

Each disc brake uses a caliperwith a single hydraulic cylinder. Brake pads in the left front and right rear contain wear sensors. When the pads need replacement, the sensors illuminate a light on the dashboard.

Tires and Wheels Tire size is critica¡ to the proper operatíon of the E36 ABS or ABS/AST system . Severa¡ different styles of wheels, in 15,16 and 17 inch diameters, are available from an authorized BMW dealer. NOTEAftermarket wheels should be selected wlth care. Improperly fitted wheels can contact and damage sus pension, brakeorbodycomponentsandmayadversely affect vehicle stability.

INTEGRATED SYSTEMS Antilock Brake System (ABS) is standard on all E36 cars . Standard on some models and installed as optional equipment on others, is All Season Traction (AST).

Antilock Brake System (ABS) The electronically-controlled ABS maintains vehícle stabili ty and control during emergency braking by preventing wheel lock-up. ABS provides optimum deceleration and stability dur-

INTEGRATED SYSTEMS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

SUSPENSION, STEERING AND BRAKES-GENERAL

300-3

UNI

0006563

Fig. 3. Schematic view of dual circuit brakes with 4-channel ABS. ing adverse conditions . It automatically adjusts brake system hydraulic pressure at each wheel to preventwheel lock-up. The system's main components are the wheel speed (pulse) sensors, the ABS control module, and the hydraulic control unit . See Fig. 4. Electronic control module

The wheel speed sensors continuously send wheel speed signals to the control module. See Fig. 5 . The control module compares these signals to determine, in fractions of a second, whether any of the wheels are about to lock . If any wheel is nearing a lock-up condition, the module signals the hydraulic unit to maintain or reduce pressure at the appropriate wheel(s) . Pressure is modulated by electrically-operated solenoid valves in the hydraulic unit .

Warning lamp Wheel brake caliper

_ Whee l speed sensor

u I-lydraulic control unit

Fig. 4. Schematic representation of ABS.

Master cylinder 0012135

Fig. 5. ABS wheel speed sensor.

INTEGRATED SYSTEMS

300-4

SUSPENSION, STEERING AND BRAKES-GENERAL

Three-channel ABS ís used on al[ E36 cars equipped with standard ABS. Each front wheel has a separate solenoid valve to modulate hydraulic pressure to that brake caliper. The rear wheels are modulated as a pair, controlled by a single solenoid valve. E36 cars equipped with ABS/AST utilize a four channel system, which functions exactly as the three channel system above, except that the rear wheels are modulated individually .

Al¡ Season Traction (AST) The traction control system works in conjunction with ABS and the engine management system to enhance vehicle con trol . The main function of the AST system is to maintain the rolling contact between the tires and the road surface under al¡ driving conditions . This is achieved through exact application and management of braking and drivetrain forces . 6.

The throttle control system used in AST is illustrated in Fig.

MASS AIR FLOW SENSOR

IDLE SPEED CONTROL VALVE HROTTLE PLATE

JADS THROTTLE PLATE POSITION SENSOR

Í I I I

THROTTLE PLATE POSITION SENSOR

ADS ACTU ATO R

DME 0013006

Fig . 6 . All Season Traction (AS) works with other drivetrain systems to enhance vehicle control.

INTEGRATED SYSTEMS

SUSPENSION, STEERING AND BRAKES-GENERAL NOTEThe traction control system referred to as AST (all season traction) may also be referred to as ASC (Automatic Stability Control) and ASC+T (Automatic Stability Control+Traction). The AST system improves traction by electronically applying the rear brakes when the rear drive wheels are spinning at a faster rate than the front wheels . The combined ABS/AST control module, operating through the ABS hydraulic control unit, modulates braking force at the rear wheels . In addition, AST uses retarded ignition timing and an auxiliary engine throttle plate to reduce engine torque and maintain vehicle stability . The auxiliary throttle plate is held open by spring pressure . The AST system actívates the auxiliary throttie position motor (ADS) to cose the AST throttle as needed . This reduces the volume of engine intake air . Due to the throttle closing very rapidly during AST operation the driver cannot increase the engine power output regardless of how far the accelerator pedal is pushed to the floor . The auxiliary throttle plate is placed ahead of the conventional throttle plate in the throttle body . Traction control also comes into operation during deceleration . Decelerating on snowy or icy road surfaces can lead to rear wheel slip . If a rear wheel starts to drag or lock up when the throttle is closed rapidly or during downshifting, the AST system can limit the problem by advancing the ignition timing . A switch on the center console is used to toggle the AST on or off . The AST system is designed to be maintenance free . There are no adjustments that can be made . Repair and troubleshooting of the AST system requires special test equipment and knowledge and should be performed only by an authorized BMW dealer. Table a lists the conditions indicated by the AST indicator light in the instrument cluster

Table a .

Indicator lamp

AST Indicator

Lamp

Condition

300-5

Function

Comment

Light on

Normal AST startup

Automatic AST self-test

Light off

AST monitoring mode

Automatic AST operation

Press AST button, light comes on

AST off (disabled)

Rocking the car to get out of snow or other loose surface Driving with snow chains

AST monitoring

Automatic AST operation

AST active mode

I Normal AST operation as it controls wheel speed

Defect in AST

Consult BMW dealer for diagnosis/repair (Vehicle operation remains normal)

Press AST button : light goes out Light flashes

I mode

Light stays on after start up or comes on while driving

WARNING -

Even a car with AST is subject to the normal physical laws. Avoid excessive speeds for the road conditions encountered. CAUTION" If the tires on the car are of different makes, the AST system may over-react. Only fit tires of the same make and tread pattem, " In adverse conditions, such as trying to rock the car out of deep snow or another soft surface, or when snow chains are fitted, it is advisable to switch off AST and allow the cars driveline to operate conventionally.

INTEGRATED SYSTEMS

SUSPENSION, STEERING AND BRAKES-GENERAL

300-6

BATTE RY KL 30

ECM MAIN RELAY

KL 15

DSC SWITCH POWER SUPPLY LF

l' z sJ

GROUND CONTROL

WHEEL

c_ .

nSLn

1;1~lZZ~

I' 1 ABS PUMP F f GROUND CONTROLÍ iJ RELAY POWER SUPPLY

SPEED

r_ .

SOLENOID RELAY

SENSORS

INLET (4X)

AST

OUTLET (4X)

wxxuw -=-=--

INTAKE

000001-f

SWITCHING

=--!99001!J

AST IHYDRAULIC 1 UNIT

WHEEL SPEED X 4 ELECTRONIC BRAKE LIGHT SWITCH

771

AGS

PARK BREVE SWITCH

r `

EDC IKE & DMEI

DME II

M ALTERNATOR INDICATOR

ABS PUMP RELAY

AUXILIARY THROTTLE POSITION MOTOR (ADS) DIAGNOSIS

lu~~~b 0013027

Fig. 7. Schematic of AII Season Traction (AST) system . INTEGRATED SYSTEMS

SUSPENSION, STEERING AND BRAKES-GENERAL M3 SUSPENSION AND BRAKES The E36 M3 was introduced in late 1994 as a 1995 model . The design of the M3 suspension, steering and brakes is a modification of existing E36 systems which accommodates increased power output and road-handling demands. The steering geometry is modified by changing the caster/camberangles slightly. This is accomplished by repositioning the upper strut mounting holes in the front strut towers and through differentfront and rear control arms . M3 Front Suspension Improvements " Reinforced spring plates, control arms, control arm bushings, steering arms . " Recalibrated struts, firmer springs. " Stiffer stabilizer bar, larger stabilizer bar bushings . " Front stabilizer linked to struts .

M3 Rear Suspension Improvements " Reinforced trailing arms . " Recalibrated shock absorbers, firmer springs.

M3 Brake System Improvements " Vented directional front rotors: 315 mm dia. x 28 mm thick. " Vented directional rear rotors: 312 mm dia. x 20 mm thick. " Larger brake pads and calipers . " Modified Teves ABS system .

300-7

NOTEM3 brake rotors are directional, having a different part number for each side. Rotors with an odd partnumber go on the left while rotors with en even part numbergo on the right. M3 Wheels/Tires " Front wheels 1992-1998: . . . . . 7.5J x 17 in . light alloy " Rear wheel 1992-1997. . . . . . . 7.5J x 17 in . light alloy " Rear wheel (option) . . . . . . . . .8 .5 J x 17 in . light alloy " Front and rear tire 1992-1997 . . . . . . . . . . . . . . . . . . . . . . 235/40 x 17 in . " Front tire 1998 only . . . . . . . . . . . . . . . 225/45 x 17 in . " Rear tire 1998 only . . . . . . . . . . . . . . . . 245/40 x 17 in .

CAUTIONIn en emergency, an M3 front wheel/tire assembly may be mounted on the rearaxle. However a rear wheel/tire assembly must not be mounted on the front axle.

SUSPENSION AND STEERING TROUBLESHOOTING Stable handling and ride comfort both depend on the integrity of the suspension and steering components. Any symptom of instability or imprecise road feel may be caused by worn or damaged suspension components . When troubleshooting suspension and steering problems, also consider the condition of tires, wheels, and their alignment . Tire wear and incorrect inflation pressures can dramatically affect handling . Subtie irregularities in wheel alignment angles also affect stabílity. Mixing different types or sizes of tires, particularly on the same axle, can affect alignment and may unbalance a car's handling . Table b lists the symptoms of common suspension and steering problems and their probable causes, and suggests corrective actions. Bold type indicates the repair groups where applicable test and repair procedures can be found.

SUSPENSION AND STEERING TROUBLESHOOTING

300-8

SUSPENSION, STEERING AND BRAKES-GENERAL Table b. Suspension and Steering Troubleshooting Symptom

Car pulís to one side, wanders Steering heavy, poor returnto-center Front-end or rear-end vibration or shimmy

Probable cause a . Incorrect tire pressure b. Incorrect wheel alignment c . Faulty brakes (pulls only when braking) a . Worn upper strut bearing(s) b. Incorrect tire pressure c . Power steering system faulty a . Worn strut cartridges or shock absorbers b. Worn suspension bushings (control arm or trailing arm) c . Worn front suspension ball joints (control arm, steering arm or steering tie-rod end) d . Unbalanced or bent wheels/tires

e . Loose wheel lug boits Poor stability, repeated bounc- I a . Worn strut cartridges or shock absorbers ing after bumps, suspension bottoms out easily Suspension noise (especially a . Worn front upper strut bearings over bumps) b. Loose front strut cartridge c . Worn suspension bushings (control arm or trailing arm) d . Worn stabilizer bar rubber mounts e . Loose suspension crossmember Uneven ride height

a . Incorrect coil springs b. Bent or damaged suspension components c . Sagging coil springs

Wheel noise, continuous I a . Worn wheel bearing growling, may be more notíceable when turning Steering loose, imprecise a . Incorrect tire pressure - b. Loose steering gear mounting bolt(s) c . Worn tie rod end(s) d . Faulty front wheel bearing e. Worn or damaged steering gear f. Worn tires

SUSPENSION AND STEERING TROUBLESHOOTING

Repairs (Repair Groups shown in bold) a. Check and correct tire pressures . 020 b . Check and adjust wheel alignment . 320 I c . Check for sticking/damaged front caliper. 340 a. Replace strut bearings . 310 b . Check and correct tire pressures . 020 c . Check power steering fluid level . Test system pressure . 320 a. Replace strut cartridges . 310, 330 b . Replace worn bushings . 310, 330 c . Replace worn ball joints. 310 d . Balance tires . Check tires for uneven wear patterns . Check wheels for damage . e . Tighten lug boits to proper torque . I a. Replace strut cartridges . 310, 330 a. Replace upper strut bearings . 310 b . Check/tighten strut cartridge collar nut . 310 c . Replace worn bushings . 310, 330 d . Replace stabilizer bar rubber mounts. 310, 330 e. Check crossmember for damage. Tighten mounting boits . a. Measure ride height and replace springs as required . 310, 330 b . Inspect, repair/replace as necessary. 310, 330 c . Measure ride height and replace springs as required . 310, 330 I a. Replace wheel bearing . 310, 330 a . Check and correct tire pressures . 020 b . Inspect and tighten boits . 320 c . Replace tie rod(s) and align wheels. 320 d . Replace wheel bearing . 310 e . Adjust or replace steering gear. 320 f . Replace tires . 010

FRONT SUSPENSION

310-1

310 Front Suspension GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310-1

FRONT WHEEL BEARINGS . . . . . . . . . . . . 310-8 Front wheel bearing, replacing . . . . . . . . . . . . . 310-8

SHOCK ABSORBERS AND SPRINGS . . . 310-2 Strut assembly, removing and installing . . . . . 310-2 Strut assembly, disassembling and assembling . . . . . . . . . . . . . . . . . . . . . . 310-4 Ride Height . . . . . . . . . . . . . . . . . . . . . . . . . . . 310-4

STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . 310-9 Stabilizer bar, removing and installing . . . . . . . 310-9 SUBFRAME CROSSMEMBER . . . . . . . . . . . 310-9 Subframe crossmember, removing and installing . . . . . . . . . . . . . . . . . 310-9

CONTROL ARMS . . . . . . . . . . . . . . . . . . . . . 310-5 Control arm, removing and installing . . . . . . 310-5 Outer control arm ball joint, replacing exce t M3 models 310-6 Control arm bushing, replacing . . . . . . . . . . . . 310-7

Table a. Front Ride Height Specifications . . . . . . . . . . . . . . . 310-5

GENERAL The E36 front suspension is shown in Fig . 1 . For a general description of the front suspension and components, see 300 Suspension, Steering and Brakes-General .

Special service tools are required for most of the work described in this repair group . Read the procedures through before beginning any job .

Control arm

Strut assembly

Stabilizer bar Power steering fluid cooler Tie rod

Fig . 1 .

Steering arm

0012132

BMW E36 front suspension . (M3 suspension shown . Others are similar.)

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

310-2

FRONT SUSPENSION

WARNING-

" Physical safety could be impaired if procedures described here are undertaken without the proper service tools and equipment. Be sure to have the right tools on hand before beginning any job. " Do not reuse self-locking nuts or bolts . They are designed to be used only once and may fail if reused. Always replace self-locking fasteners any time they are loosened or removed. " Do not install bolts and nuts coated with undercoating wax, as the correct tightening torque cannot be assured. Always clean the threads with solventbefore installation, or install new parts . " Do not attempt to weld or straighten any suspension components. Replace damaged parts.

SHOCK ABSORBERS AND SPRINGS The complete front strut assembly is shown in Fig. 2. Most strut assembly components are available as replacement parts. NOTEStruts andlor springs should always be replaced in parts .

Strut assembly, removing and installing 1 . Raise car and remove front wheel. WARNING-

Make sure that the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point Do not place jack stands under suspension parts.

2. Unbolt brake caliper assembly, keeping brake hose connected. Detach brake hose from strut assembly . Suspend brake caliper from chassis using stiff wire . Remove brake rotor. See 340 Brakes .

0011191

Fig. 2. Front strut assembly with steering arm, front hub, front spring and strut upper mount. 3. Remove ABS wheel speed sensor. See Fig. 3. 4. Disconnect ABS sensor wire harness and brake pad wear sensor wire harness (left side only) from strut housing. 5. On M3 modeis : Disconnect stabilizer bar link from strut. SHOCKABSORBERS AND SPRINGS

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FRONT SUSPENSION

Fig . 3 . ABS wheel speed sensor mounting bolt (arrow) .

310-3

0012117

NOTENote flats on stabilizer bar link ball joint for placement of open end wrench . 6 . Unbolt splash shield and steering arm from strut . Suspend steering arm assembly from chassis using stiff wire . See Fig . 4 . CAUTIONThe steering arm ball joint can be damaged if the arm is allowed to hang unsupported. 7 . Support strut assembly from below. From above, remove three strut mounting nuts on strut tower. CAUTIONDo not remove center strut retaining nut. 8 . Lower strut assembly from car. NOTEStore the removed strut assembly upríght. Do not allow it to líe horizontally or upside-down for any length of time . If íncorrect storage has occurred, place the strut assembly upríght wíth the rod fully extended for at least 24 hours.

1. 2. 3. 4. 5.

Nut Strut ABS wheel speed sensor Cable holder Steering arm

6 . Bolt 7 . Bolt 8 . Flat washer 9 . Self-locking nut 10. Washer 11 . Bolt

Fig . 4 . Strut and steering arm assembly. 9 . Installation is reverse of removal . Be sure to use new self-locking nuts and bolts . " Use new steering arm mounting bolts, or clean bolts and use Locktite® 270 or equivalent thread-locking compound . " On M3 models : When attaching stabilizer link to strut, use a thin wrench to hold flats on link parallel to strut . " Have car professionally aligned When job is complete .

Tightening Torques " Brake caliper to steering arm . . . . . . 110 Nm (81 ft-lb) " Road wheel to hub . . . . . . . . . 100±10 Nm (74 t7 ft-Ib) " Stabilizer bar link to strut (M3) . . . . . . 59 Nm (44 ft-lb) " Steering arm to strut housing " (encapsulated bolts-always replace) 107 Nm (78 ft-lb) " Strut assembly to strut tower (self-locking nuts) . . . . . . . . . . . . . . . . 24 Nm (16 ft-Ib)

SHOCK ABSORBERS AND SPRINGS

310- 4

FRONT SUSPENSION 6. Assembly is reverse of disassembly, noting the following:

Strut assembly, disassembling and assembling

- Be sure upper spring pad is correctlyinstalled to upper

spring plate and spring end is correctly seated in upper and lower spring plates . " Use a new self-locking top (center) nut. Tighten nut fui¡y before releasing spring compressor. " Have car professionally aligned when job is complete .

NOTESprings andlor struts should always be replaced in pairs.

Replacing the upper strut mount, spring and strut requires that the strut first be disassembled . For a guide to the parts during strut replacement, see Fig. 5.

Tightening Torques " Upper strut mount to strut shaft (seif-locking nut) shaft with external hexagon . . . . . . . . 65 Nm (48 ft-1b) shaft with interna¡ hexagon . . . . . . . . . 44 Nm (32 ft-Ib) " Road wheel to hub . . . . . . . . .100±10 Nm (74 ±7 ft-lb)

WARNINGDo not,attempt to disassemble the struts without a springcompressordesignedspecificallyforthisjob .

1 . Remove strut assembly as described earlier. Place in secure support. 2. Using spring compressor, compress spring until spring force on upper mount is relieved . WARNING Make sure the spring compressor grabs the spring fully and securely before compressing it.

3. Pry protective cover off top of strut assembly, then remove top (center) nut and washer while holding strut shaft stationary 4. Remove upper strut mount and related components . 5. Release spring compressor carefully and evenly, allowing spring lo expand slowly

Cover Self-locking hex nut Flat washer Nut Upper strut mount

Pin Flat washer

Upper spring plate

Ride Height Ride height is measured from the lower edge of the wheel arch to the bottom edge of the wheel rim . See Fig. 6. lf the ride height is outside the specification listed, new springs should be installed. Be sure to have the old spring code number on hand when ordering new spring . NOTEThe spring part number is stamped near the end of the spring cofls .

Table a lists front suspension ride height specifications . These specifications apply to a car in a normally loaded position . When checking ride height or installing suspension components that require the car to be "normally loaded," load the car as follows:

Absorber/ bump stop

~ Piston bellows r

Upper spring pad

1 -Í

Fig. 5. Front spring, spring plate and related parts. SHOCKABSORBERS AND SPRINGS

Lower spring pad 0012136

FRONT SUSPENSION

310-5

CONTROL ARMS On al¡ models except Mas, the outer mounting bushing and the outer ball joint on the control arm are available as replacement parts . If the control arm center ball joint is worn, the complete control arm will need to be replaced . See Fig . 7 .

Fig . 6.

Ride height measurement (A) is taken from center of wheel arch to bottom of wheel rim .

Normal loaded position " Each front seat . . . . . . . . . . . . . . . . . . . 68 Kg (150 Ibs) " Rear seat (center) . . . . . . . . . . . . . . . . 68 Kg (150 Ibs) " Trunk . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Kg (46 lbs) " Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .fuf

Table a . Front Ride Height Specifications Wheel size

318, 323, 325, 328 models

M3 models

15 inch std . suspension sport suspension

576 mm (22.67 in) ~ 561 mm (22.09 in)

1555 mm (21 .85 in) 530 mm (20 .87 in)

16 inch std . suspension sport suspensíon

589 mm (23.19 in) ~ 574 mm (23.52 in)

1570 mm (22 .44 in) 545 mm (21 .46 in)

17 inch std . suspension sport suspension

604 mm (23.77 in) ~ 589 mm (23.19 in)

585 mm (23 .03 in) ~ 560 mm (22 .05 in)

Maximum variation between sides : 10 mm (0 .4 in) Maximum deviation from specifications : 10 mm (0.4 in)

Fig . 7. Control arm . Outer ball joint and bushing are available as replacement parts (except M3) . Center ball joint is integral with control arm . Special press tools are required to remove the control arms and to replace the control arm bushings . Read the procedure through before beginning the job .

Control arm, removing and installing 1 . Raise car and remove wheel . WARNINGMake sure that the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts . 2 . Remove stabilizer bar link mounting nut and separate link from control arm as described later in this repair group. NOTEOn M3 models, the stabilizer bar link attaches to the strut.

CONTROL ARMS

310-6

FRONT SUSPENSION

3. Working at steering arm, remove control arm ball joint nut. See Fig. 8. Press ball joint out of steering arm.

Tightening Torques " Control arm ball joint to subframe crossmember . . . . . . . . . . . 85 Nm (62 ft-Ib) " Control arm'ball joint to steering arm . 65 Nm (48 ft-Ib) " Control arm bushing carrier to body . . 47 Nm (34 ft-Ib) " Stabilizer bar link to control arm (M8) . 42 Nm (31 ft-Ib) " Road wheel to hub . . . . . . . . . 100±10 Nm (74±7 ft-Ib)

Outer control arm ball joint, replacing (except M3 models) On all models except Mas, the outer ball joint is available as a replacement part. The ball joint can be replaced with the control arm installed.

Fig. 8. Control arm ball joint nut at steering arm (arrow).

0012117

4. Remove control arm to subframe crossmember ball joint nut. Separate ball joint from crossmember. Working at other end of control arm, remove bolts attaching control arm bushing carrier to body. See Fig . 9.

Special tools are required to replace the ball joínt. Read the procedure through before beginning the job. 1 . Disconnect stabilizer bar link from control arm as described later in this repair group. NOTEOn M3 models, the stabilizer bar link attaches to the strut. tt fs not necessary to disconnect the stabilizer bar link on M3 models for thfs repair procedure.

2. Loosen nut for ball joint until it contacts steering arm. 3. Using a suitable ball joint tool, separate joint from steeríng arm. Remove ball joint mounting nut and pull ball joint out of steering arm. 4. Mark position of ball joint guide to control arm. See Fig. 10 .

Fig. 9. Control arm bushing carrier bolts (arrows) .

0011960

5. Installation is reverse of removal. Make sure al¡ thread bores, bolts, nuts and mating surfaces are clean. Use new self-locking nuts or bolts, where applicable . WARNING" Do not reuse self-locking nuts or bolts. They are designed to be used only once and may fail if reused. " Bolts and nuts coated with a focking compound from the factory should not be refnstalled. Always replace `micro-encapsulated" fasteners such as the steering arm-to-strut bolts. CONTROL ARMS

0012718

Fig. 10 . Mark installed position of ball joint guide to control arm (srrow) . 5. Move suspension strut out of way and press ball joint out of control arm.

FRONT SUSPENSION 6. Installation is reverse of removal.

" Make sure control arm ball jointtaper bore is clean and free of any corrosion. " Press new ball joint into position, making sure to align ball joint guide with mark made earlier. " Verify that locking clip on new ball joint faces towards center of vehicle.

Tightening Torques " Control arm ball joint to steering arm . 65 Nm (48 ft-Ib) " Stabilizer bar link to control arm (M8) 42 Nm (31 ft-Ib) " Road wheel to hub . . . . . . . . . 100±10 Nm (74t7 ft-lb)

Control arm bushing, replacing Control arm bushings should aiways be replaced in pairs and the two bushings and bushing carriers should have the same markings, indicating same manufacturer .

310-7

NOTE-

The kerosene-like special lubricant is used only as an aid in installing the bushing to the control arm stub. Work must be carried out in as short a time as possible . Within 30 minutes the control arm bushing will be `glued" in position on the control arm.

CAUTION-

BMW part numbers are provided for reference only and are subject to change. Always rely on an authorized BMW dealer parts department for the most up-to-date information .

6. Press new rubber control arm bushing assembly onto the end of control arm to proper depth (as marked). NOTE-

Be sure to reinstall the bushing carrier to the control arm correctly. The carrier has centering bores on side . This side must face up towards body. See Fig . 12.

1 . Raise car. WARNINGMake sure that the car is firmly supported on jack stands designed for the purpose . Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.

2. Unbolt control arm bushing carrier from body. 3. Mark installed position of bushing to control arm. See Fig. 11 .

lnl~

0012145

Fig. 11 . Before removing bushing from control arm, mark installed position of old bushing to control arm . Insta¡¡ new bushing in same position .

4. Using appropriate press tools, pull control arm bushing assembly off control arm. 5. Coat end of control arm with BMW special lubricant part no . 81 22 9 407 284.

Fig . 12 . Control arm bushing carrier centering bores must face up .

7. Immediately bolt control arm bushing carrier to body, torque boits and lower car to ground . Tightening Torques " Control arm bushing carrier to body . . 47 Nm (34 ft-ib) 8. With car lowered to ground and loaded as described earlier, bounce suspension a few times, then leave car undisturbed for a minimum of 30 minutes. CAUTION-

I Failure to follow the above procedure may impair the car's handling and stability.

CONTROL ARMS

310-8

FRONT SUSPENSION

FRONT WHEEL BEARINGS The front wheel bearings are permanently sealed and require no maintenance . The bearing is integral with the wheel hub and pressed onto the steering arm stub axle . Special press tools are required to replace the front wheel bearings. Read the procedure through before beginning the job . Front wheel bearing, replacing

6. Remove ABS wheel speed sensor. Refer to Fig. 3. 7. Remove brake caliper assembly and brake rotor as described in 340 Brakes . Leave brake hose connected to caliper. Suspend caliper assembly from chassis using stiff wire . 8. Remove wheel hub collar nut. 9. Remove wheel hub with integral wheel bearing from steering arm using a puller. See Fig. 14 .

1 . Raise car and remove wheel. WARNINGMake sure that the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.

2. Pry off dust cap from center of wheel hub. Bend back staked part of wheel hub (axle) collar nut. See Fig. 13 .

0011200

Fig. 14 . Wheel hub with integral wheel bearing being removed using a puller.

NOTE-

If bearing inner race stays on steering arm, remove splash guard and use twojaw puller to remove race.

10 . Insta¡¡ splash guard and new dust shield behind bearing. Press new wheel hub/bearing assembly on using appropriate press tools. Fig. 13 . Staked part of wheel hub collar nut to be bent back (arrow) . 3. Remount wheel and lug bolts. 4. Lower canto ground . With an assistant applying brakes, loosen collar nut. Do not remove completely.

NOTE-

The wheel hub collar nut is tightened to a torque of 290 Nm (214 ft-Ib) . Make sure the car is firmly on the ground.

5. Raise car and remove wheel.

FRONT WHEEL BEARINGS

NOTE-

When pressing the wheel hublbearing on, apply force only to the bearing inner race.

11 . Install new collar nut. Do not tighten nut to its final torque at this time . " Install brake rotor and brake caliper. See 340 Brakes . " Mount wheel and lug boits. Lower canto ground to gain leverage.

12 . With an assistant applying brakes, tighten collar nut and then stake nut to axle . 13 . Raise car and remove wheel .

FRONT SUSPENSION 14 . Insta¡¡ a new grease cap, using Loctite© 638 sealant or equivalent . Insta¡¡ wheel and lower car. Tightening Torque " Brake rotor lo wheel hub . . . . . . . . . . 16 Nm (12 ft-Ib) " Collar nut lo stub axle . . . . . . . . . . 290 Nm (214 ft-Ib) " Brake caliper lo steering arm . . . . . . 110 Nm (81 ft-Ib) " Road wheel lo hub . . . . . . . . . 100±10 Nm (74t7 ft-Ib)

STABILIZER BAR Stabilizer bar, removing and installing Stabilizer bar link arrangements differ slightly among models. In most models the links attach lo the control arms near the outboard end. On M3 models the links attach lo the strut assemblies . 1 . Raise car and remove both front wheels. WARNING Make sure that the car is firmly supported on jack stands desígned for the purpose. Place the jack stands beneath a structural chassís point. Do not place jack stands under suspension parts.

310-9

3. Remove two stabilizer bar bushing brackets on left and right sides. Remove bar. 4. Installation is reverse of removal . Use new seif-lockíng núts on connecting links. " On M3 models : When attaching stabilizer link lo strut or lo bar, use a thin wrench lo hold flats on link parallel lo strut. NOTEInstallation of the stabilizer bar is easiest with the car leve¡ (front wheels at the same height), and as near to normal ride height as possible.

Tightening Torques " Stabilizer bar bushing brackets lo subframe crossmember . . . . . . . . . 22 Nm (16 ft-Ib) " Stabilizer bar link bracket lo control arm . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 ft-1b) " Stabilizer bar link lo stabilizer bar (M10) . . . . . . . . . . . . . . 42 Nm (31 ft-Ib) " Stabilizer bar link lo strut or bar (M3) . 59 Nm (44 ft-Ib)

SUBFRAME CROSSMEMBER

2. Remove stabilizer bar connecting link from stabilizer bar on left and right sides. See Fig. 15 .

The subframe crossmember provides rigid mounting'poínts for the engine, suspension, and steering components . The crossmember is not normally subject lo wear and should ohly be replaced if structurally damaged. Removing the subframe crossmember requires engine lifting equipment lo support the weight of tfhe engine from above so that the subframe can be removed from below. WARNINGRemoval or replacement of the subframe crossmember may affect suspension and steering geometry, including front wheel afignment. Make appropriate matching marks during removal and have the front end aligned once repairs are complete.

Subframe crossmember, removing and installing 1 . Using engine support equipment, raise engine until weight of engine is supported . See 110 Engine Removal and Installation . See Fig. 16 . uul

Fig. 15. Disconnect stabilizer bar connecting link at bar (arrow). (3181 model shown. M3 stabilizer link attaches lo strut.)

2. Raise car and remove front wheels . WARNINGMake sure that the car is firmly supported on jack stands desígned for the purpose . Place the jack stands beneath a structural chassís point Do not place jack stands under suspension parts .

SUBFRAME CROSSMEMBER

310- 1 0

FRONT SUSPENSION

Fig. 16 . Support equipment used to support engine from aboye. 3. Working beneath car, remove left and right nuts from engine mounts. 4. Remove control arm bushing carrier from body. Refer to Fig. 9. 5. Remove control arm ball joint from crossmember. Separate joint with a plastic hammer. Suspend control arm from chassis using stiff wire . WARNINGDo not allow the control arm to hang from the ball ¡oint. This can damage the ball¡oint.

6. Unbolt steering rack from subframe . See 320 Steering and Wheel Alignment. Suspend steering rack from chassis using stiff wire . Using a transmission jack or equivalent, support crossmember from below. 7. Remove reinforcing brace below oil pan, where applicable. 8. Unbolt crossmemberfrom body on both sides. See Fig. 17 . 9. Slowly Lower crossmember, making sure all electrical teads, suspension components and heat shields are clear during removal .

Fig. 17. Right side crossmember-to body mounting bolts. 10 . Installation is reverse of removal, noting the followíng:

" Make sure all bolts, bolt holes, and mating surfaces are clean to ensure proper tightening and alignment. Use new self-locking nuts or bolts, where applicable . " On vehicles produced up 9-92 only : -Remove paint from contact surfaces before ínstalling crossmember. -Install 4 new toothed lock washers between subframe and chassis (install new washers regardless of whether washers were originally fitted) . -Replace all 4 mounting bolts. -Lubrícate suspension crossmember bolts with LM48 paste or equivalent anti-seize compound before ínstalling . " Lower engine onto engine mounts, allowing it to settle fully before tightening engine mount bolts. " When the job is completed have front end professionally aligned.

Tightening Torques " Subframe crossmember to body M12-8.8 bolts . . . . . . . . . . . . . . . . . . . 77 Nm (56 ft-Ib) M12-10 .9 bolts . . . . . . . . . . . . . . . . . 110 Nm (81 ft-Ib) M12-12 .9 bolts . . . . . . . . . . . . . . . . . 105 Nm (77 ft-Ib) " Steering gear to subframe crossmember (M10-10.9 self-locking bolts) . . . . . . . 42 Nm (31 ft-Ib) " Control arm ball joint to subframe crossmember . . . . . . . . . . . 85 Nm (62 ft-Ib) " Control arm bushing carrier to body . . . . . . . . . . . . . . . . . . . . . . . . 47 Nm (34 ft-Ib)

SUBFRAME CROSSMEMBER

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

STEERING AND WHEEL ALIGNMENT

320-1

320 Steering and Wheel Alignment GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320-1

Outer tie rod end, replacing . . . . . . . . . . . . . . . 320-4 Tie rod, replacing . . . . . . . . . . . . . . . . . . . . . . . 320-5

STEERING WHEEL 320-1 Steering wheel, removing and installing . . . . . 320-1

WHEEL ALIGNMENT. . . . . . . . . . . . . . . . . . .320-5

POWER STEERING SYSTEM . . . . . . . . . . . 320-2

Front Toe-in and Toe Difference Angle . . . . . . 320-6

Power steering pump, removing and installing . . . . . . . . . . . . . . . . 320-2 Power steering system, bleeding and filling . . 320-3

STEERING GEAR . . . . . . . . . . . . . . . . . . . . . 320-3 Steering gear rack, removing and installing . . . . . . . . . . . . . . . . . . 320-3

Caster and Camber . . . . . . . . . . . . . . . . . . . . . 320-5

Rear Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . 320-6 Wheel Alignment Specifications . . . . . . . . . . . . 320-6 TABLES a. Front Wheel Alignment Specifications . . . . . . . . . . . 320-6 b. Rear Wheel Alignment Specifications . . . . . . . . . . . 320-6

GENERAL

STEERING WHEEL

This repair group covers servicing of the mechanical and hydraulic components of the steering system, including wheel alignment information .

The BMW E36 is equipped with an SRS airbag mounted in the steering wheel. Improper handling of the airbag could cause serious injury . The airbag is an explosive device and should be treated with extreme caution. Always follow the airbag removal procedure as outlined in 721 Airbag System (SRS).

The variable-assist power steering system consists of an engine-driven hydraulic pump, a rack-and-pinion steering gear assembly with an integral hydraulic control valve, and connecting linkage to the road wheels . At low speeds, maximum power assist is provided to ease parking and city driving. At high speeds, assist is reduced to ensure stability . The power steering system varies assist based on engine speed . WARNING" Do not reuse self-locking nuts. They are designed to be used only once and may fail if reused. Always replace them with new locking nuts . " Do not ínstall bolts and nuts coated with undercoating wax, as correct tightening torque cannot be assured. Always clean the threads with solvent before installation, or install new parts. " Do not attempt to weld or straighten any steering components. Always replace damaged parts.

NOTE-

For information on steering column-mounted switches and the ignition lock, see 612 Switches and Electrical

Accessories.

WARNING" The BMW Supplemental Restraint System (SRS) is complex and special precautions must be observed when servicing. Serious injury may result if system service is attempted by persons unfamiliar with the BMW SRS and its approved service procedures. BMW specifies that all inspection and service should be performed by an authorized BMW dealer. " BMW Supplemental Restraint Systems (SRS) are equipped with a back-up power supply inside the SRS control module . A 10 minute waiting should be observed after the battery cable has been disconnected. This will allow the reserve power supply to discharge.

Steering wheel, removing and installing 1 . Center steering wheel . Make sure front wheels are pointed straight ahead. 2. Disconnect negative (-) cable from battery and cover terminal with insulating material .

CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

STEERING WHEEL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

320-2

STEERING AND WHEEL ALIGNMENT

3. Carefully remove airbag from front of steering wheel. See 721 Airbag System (SRS). Store airbag unit in a safe place. WARNINGImproper handling of the aírbag could cause serious ínjury. Store the aírbag with the horn pad facing up . If stored facing down, accidental deployment could propel it vlolently into the air, causíng ínjury.

4. Remove steering wheel center bolt . Lightly punch mark or scribe position of steering wheel to steering column shaft. See Fig. 1 .

Fig. 2. Insta¡¡ steering wheel so that locking pin in column aligns with cutout in contact reel (arrow). Contact reel on late model steering wheel may vary from that shown.

POWER STEERING SYSTEM Power assist is províded by a belt-driven pump on the lower left front of the engine, just below the alternator. The power steering fluid resenroir is located on the lower left front of the engine . Fig. 1 . Steering wheel center bolt (arrow).

0012687

5. Unlock steering wheel by turning ignition key on . Remove steering wheel. WARNINGThe SRS contact reel ís mounted to the rear of the steering wheel hub. The contact reel ís a wound coil of wire that ensures continuous electrícal contact for the air bag unit Once the steering wheel mounting nut or bolt is removed the contact reel is locked in the center position and its position must not be altered.

6. Insta¡¡ steering wheel while aligning matching marks. Make sure airbag contact ring locking pin engages cut out in contact reel . Insta¡¡ steering column center nut. Do not over-torque . See Fig . 2 . 7. The remainder of installation is reverse of removal. Carefully install airbag from front of steering wheel. See 721 Airbag System (SRS). Tightening Torque " Steering wheel to steering column spindle . . . . . . . . . . . . . . . . . . 63 Nm (46 ft-Ib)

POWER STEERING SYSTEM

Power steering pump, removing and installing 1 . Empty power steering fluid reservoir using clean syringe. Do not reuse fluid. 2. Raise front of car. WARNING Make sure the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands undersuspension parts.

3. Remove fluid hoses frbm pump. Plug openings in pump and in hose ends. 4. Remove drive belt from power steering pump . See 020 Maintenance Program . 5. Remove pump mounting bolts and remove pump . See Fig . 3.

STEERING AND WHEEL ALIGNMENT

320- 3

STEERING GEAR A cutaway of the power-assisted rack-and-pinion power steering gear is shown in Fig . 4. The rack is designed to be maintenance free .

Pinion

Fig. 3. Power steering pump and pulley mounting bolts. 6. Installation is reverse of removal, noting the following:

" Make sure al¡ thread bores, bolts, nuts, fluid couplings and mating surfaces are clean, and that inside surface of multi-ribbed-belt is free of grease and dirt . " Use new sealing washers when reattaching power steering pressure lines. " Make sure hoses have adequate clearance from chassis. Do not over-torque banjo bolts. " Fill and bleed power steering system as described below.

Tightening Torques " Hydraulic hoses to power steering pump M10 banjo bolt . . . . . . . . . . . . . . . . . . . 12 Nm (9 ft-Ib) M14 banjo bolt . . . . . . . . . . . . . . . . . . 35 Nm (26 ft-Ib) M16 banjo bolt . . . . . . . . . . . . . . . . . . 40 Nm (30 ft-Ib) " Power steering pump to bracket (self-locking nuts) . . . . . . . . . . . . . . . . 22 Nm (16 ft-Ib) " Power steering pump bracket to engine block or oil pan (self-locking nuts) . . . 22 Nm (16 ft-lb)

Power steering system, bleeding and filling

1 . Wíth engine off, fill power steering fluid reservoir with clean fluid. Fill level to MAX mark on dipstick .

2. Start engine. Slowly turn steering wheel from lock to lock a minimum of two times. 3. Turn engine off and check fluid leve¡, adding fluid if necessary.

Fig. 4. Cutaway of rack-and-pinion steering gear. ?he steering gear and linkage require no maintenance other than alignment and a periodic inspection for worn compo nents.

Steering gear rack, removing and installing

1 . Empty power steering fluid reservoir using clean syringe. Do not reuse fluid. 2. Disconnect negative (-) cable from battery and cover terminal with insulating material . CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

3. Carefully remove airbag from front of steering wheel. See 721 Airbag System (SRS). Store airbag unit in a sale place. 4. Make sure front wheels are pointed straight ahead. 5. Remove outer tie rod ball joínt nuts, then separate outer tie rod ends from steering arms using appropriate press tools. 6. Disconnect power steering hose from fluid reservoir . STEERING GEAR

320-4

STEERING AND WHEEL ALIGNMENT

7. Remove fluid line banjo bolt from steering gear. See Fig. 5. CAUTION-

9. Remove steering gear mounting bolts. See Fig. 7. Re move steering gear from subframe crossmember by pulling it forward.

Plug the openings in the pump and hose ends to prevent dirt from entering the hydraulic system. NOTEIt may be necessary to remove other components to gain access to the steering gear.

Fig. 7. Steering gear mounting bolts (arrows) . 10 . Installation is reverse of removal, noting the following:

Fig. 5. Fluid hoses and banjo bolts at steering gear (arrows) . 8. Remove lower steering shaft universal joint pinch bolt, then pull universal joint half way off steering gear shaft. Mark relationship between shaft and universal joint, then remove universal joint from steering gear . See Fig. 6.

" Make sure al¡ thread bores, bolts, nuts, splines and mating surfaces are clean. Use new self-locking nuts wherever applicable . " Use marks made during removal to reassemble steering column universal joint to steering stub shaft. Make sure wheels are straight ahead. " Use a new sealing washer on banjo fitting. Do not overtorque banjo bolt . " Install airbag to the steering wheel as described in 721 Airbag System (SRS). " Fill and bleed power steering system as described earlier. " Have the car professionally aligned .

Tightening Torques " Outer tie rod end to steering arm . . . . 45 Nm (33 ft-Ib) " Steering column universal joint to steering gear shaft (self-locking nut) . . . . . . . . 19 Nm (14 ft-Ib) " Steering gear to subframe crossmember M10 bolt . . . . . . . . . . . . . . . . . . . . . . . 42 Nm (32 ft-Ib) " Steering fluíd lines M10 banjo bolt . . . . . . . . . . . . . . . . . . . 12 Nm (9 ft-Ib) M14 banjo bolt . . . . . . . . . . . . . . . . . . 35 Nm (26 ft-lb) M16 banjo bolt . . . . . . . . . . . . . . . . . . 40 Nm (30 ft-Ib)

Outer tie rod end, replacing 1 . Raise car, remove outer tie rod ball joint nut, and press out outer tie rod end ball joint as described above. 2. Make a reference measurement of outer tie rod end to tie rod. See Fig. 8. Record measurement. 0013231

Fig. 6. Steering column universal joint pinch bolt (arrow). Mark Ujoint to shaft before disconnecting. With wheels in straight ahead position, mark on steering gear (A) should align with split seam in universal joint (B). STEERING GEAR

NOTEAccurate measuring of the tie rod end in reference to the tie rod will help approximate correct wheel alignment when new parts are installed.

STEERING AND WHEEL ALIGNMENT

320-5

3. Loosen rack boot bellows clamp and slide bellows back. Inspect boot for any sign of damage. Replace if necessary. 4. Unlock inner tie rod end lockplate using pliers. 5. Using special tool, unscrew inner tie rod end from steering rack . See Fig . 10 .

Lock nut

0012143

Fig. 8. Measuring tie rod end position (for reference only). 3. Loosen outer tie rod end lock nut. See Fig. 9.

Fig. 10 . Special tool (arrow) installed on inner tie rod end . 6. Installation is reverse of removal, noting the following:

Fig. 9. Outer tie rod end lock nut (arrow). 4. Unscrew tie rod end from steering gear. 5. Installation is reverse of removal. Make sure all threaded parts are clean. Have the car professionally aligned. Tightening Torques " Outer tie rod end lo steering arm . . . . 45 Nm (33 ft-Ib) " Outer tie rod end lock nut. . . . . . . . . . 35 Nm (26 ft-Ib)

Tie rod, replacing

1 . Raise car, remove outer tie rod end ball joint nut, and press out outer tie rod end ball joint as described above.

2. Make a reference measurement of outer tie rod end to tie rod. See Fig. 8. Record measurement NOTEAccurate measuring of the tía rod end in reference to the tie rod will help to approximate wheel alignment when new parts are installed.

" Make sure all threaded parts are clean. Replace selflocking nuts and inner tie rod lockplate . " Install outer tie rod end to newtie rod using reference measurement recorded earlier. " Have car professionally aligned.

Tightening Torques " Outer tie rod end to steering arm . . . . 45 Nm (33 ft-Ib) " Outer tie rod end lock nut . . . . . . . . . . 35 Nm (26 ft-Ib) " Inner tie rod to steering gear . . . . . . . 71 Nm (52 ft-Ib)

WHEEL ALIGNMENT Proper handling, stability, tire wear, and driving ease depend upon the correct alignment of al¡ four wheels . The front axle is aligned in relation to the rear axie, then the front wheels are aligned in relation to one another. This is known as a fourwheel or thrust-axis alignment. The BMW E36 uses a sophisticated multi-link suspension at the front and rear of the car. Proper alignment requires computerized alignment equipment.

Caster and Camber Front and rear caster and Camber are both fixed by the design of the car. Any deviations are usually the result of worn or damaged suspension or body parts. WHEEL ALIGNMENT

320- 6

STEERING AND WHEEL ALIGNMENT

Front Toe-in and Toe Difference Angle

Wheel Alignment Specifications

Toe-in is the difference in the distance between the front of the front wheels and the rear of the front wheels . It is adjusted by altering the length of the outer tie rods .

Alignment specifications for the E36 are listed in Table a and Table b. The specifications only apply underthe following conditions :

Toe-in adjustments should only be made on alignment equipment with the car in normal loaded position as described below under Wheel Alignment Specifications .

" Correct wheels and tires are installed, in good condition, and are at the correct inflation pressures. " Al¡ steering and suspension parts and bushings are undamaged and show no signs of abnormal wear. " Wheel bearings are in good condition. " Ride height is in accordance with specifications . See 310 Front Suspension and 330 Rear suspension . " Car is in normal loaded position .

Toe difference angle determines the progressively different pathstaken by thefrontwheels as thecar is turning. It is fixed by the steering gear, but depends on accurate setting of the toe-in .

Rear Toe-in There is no provision for routine rear wheel toe-in adjustment . If any alignment angles deviate from specifications, carefully inspect the rear trailing arms, rear suspension subframe and al¡ associated bushings and flexible mounts for wear or damage . After replacing any parts that appear worn or damaged, re-check the toe measurements .

Normal loaded position " Each front seat . . . . . : . . . . . . . . . . . . . 68 Kg (150 lb) " Rear seat (center) . . . . . . . . . . . . . . . . 68 Kg (150 lb) " Trunk. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Kg (46 lb) " Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full

Table a. Front Wheel Alignment Specifications Model Toe angle (total)

3181325

3181325 sport suspension

M3 3.0 liter

M3 3.2 liter

0° 18'±8'

0° 10' ±5'

0° 10' t5'

To 1995

-0° 40'±30'

-0° 58'± 30'

-0° 55'±30'

1995 on

-0° 30' ±30'

-0° 51'±30'

-0° 55'±30'

-0° 46'±30'

10° wheel lock

3° 41'±30'

3° 50'±30'

6° 38'±30'

9° 35'±30'

20° wheel lock

3° 52'±30'

3° 57' t30'

6° 52'±30'

7° 50'±30'

0° t15'

0° ±15

0° ±15'

Camber -

Caster

Front Wheel Displacement

Table b. Rear Wheel Alignment Specifications Model

3181325

3181325 sport suspension

M3 3.0 liter

M3 3.2 liter

Toe angle (total)

0° 24' t6'

0° 24'±6'

0'30' .-t6'

0° 30' t6'

Camber

-l' 40' t15'

-2° 0' t15'

-1 ° 45' t10'

-1'45'±10'

0° ±3'

0° t3'

Maximum allowable deviation between sides

WHEEL ALIGNMENT

REAR SUSPENSION

330 Rear Suspension

330-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .330-1

CV boot, replacing . . . . . . . . . . . . . . . . . . . . . .330-8

RIDE HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . 330-1

REAR SUSPENSION ARMS . . . . . . . . . . . . 330-9

Rear shock absorber, removing and installing 330-3 Coil spring, removing and installing . . . . . . . . 330-4

Trailing arm, removing and installing . . . . . . . 330-10 Trailing arm bushing, replacing . . . . . . . . . . . 330-11 Upper control arm, removing and installing . .330-12 Lower control arm, removing and installing . .330-12

REAR WHEEL BEARINGS . . . . . . . . . . . . . 330-4

FINAL DRIVE CARRIER . . . . . . . . . . . . . . . 330-12

DRIVE AXLES . . . . . . . . . . . . . . . . . . . . . . . . 330-6

TABLE a. Rear Ride Height Specifications . . . . . . . . . . . . . . . 330-1

SHOCK ABSORBERS AND SPRINGS . . . 330-2

Rear wheel bearing, replacing . . . . . . . . . . . . 330-5 Drive axle, removing and installing . . . . . . . . . 330-6

Final drive carrier, removing and installing . .330-12

GENERAL Special service tools are required for some of the work described in this repair group. Read the procedures through before beginning any job. NOTE A general description of the rear suspension and a troubleshooting guide can be found in 300 Suspen-

sion, Steering and Brakes-General.

RIDE HEIGHT Rear suspension ride height is controlled by the rear springs. If the rear ride height is not within the specifications listed, the rear springs should be replaced . Ride height is measured from the lower edge of the wheel arch to the bottom edge of the wheel rim. See Fig . 1 . Table a lists rear suspension ride height specifications . These specifications apply to a car in a normally loaded position . When checking ride height or installing suspension components, load the car as follows: Normal loaded position " Each front seat . . . . . . . . . . . . . . . . . . . . 68 kg (150 lb) " Rear seat (center) . . . . . . . . . . . . . . . . . 68 kg (150 lb) " Trunk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 kg (46 lb) " Fue¡ tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full NOTEM3 ride height is measured with the car unladen .

ooy 98

Fig. 1 . Ride height measurement (A) is taken from center of wheel arch to bottom of wheel rim.

Table a. Rear Ride Height Specifications Wheel size

318, 323, 325, 328 modeis

15 inch std. suspension sport suspension

518 mm (20 .39 in) ~ 507 mm (19 .96 in)

16 inch std. suspension sport suspension

531 mm (20 .91 in) ~ 520 mm (20 .47 in)

M3 modeis

Continued RIDE HEIGHT

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

330-2

REAR SUSPENSION

Table a. Rear Ride Height Specifications Wheel size 17 inch std . suspension sport suspension

318, 323, 325, 328 modeis 546 mm (21 .69 in) ~ 535 mm (21 .06 in)

M3 modeis

1 540 mm (21 .26 in)

Maximum variation between sides : 10 mm (0.4 in) Maximum deviation from specifications: 10 mm (0.4 in)

SHOCK ABSORBERS AND SPRINGS The BMW E36 independent rear suspension is shown in Fig. 2. Refer to this illustration while performing repairs on components covered in this repair group. NOTEShock absorbers andlor springs should always be replaced in pairs

Stabilizer bar link

Lower control arm Trailing arm bushing

Fig . 2 .

BMW E36 rear suspension .

SHOCK ABSORBERS AND SPRINGS

Trailing arm front bracket

WARNING " Do not reuse self-locking nuts. They are designed to be used only once and may fail if reused. Always replace them with new self-locking nuts. " Personal injury may result if procedures described here are undertaken without the proper service tools and equipment. Be sure to have the right tools on hand before beginning the job. " Do not install bolts and nuts coated with undercoating wax, as correct tightening torque cannot be assured. Always clean the threads with solvent before installation, or ínstall new parts. " Do not attempt to weld or straighten any suspension components . Replace damaged parts .

REAR SUSPENSION

330- 3

Rear shock absorber, removing and installing 1 . Raise car and remove rear wheels . WARNING Make sure that the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.

2. Remove rear speakers . See 650 Radio. 3. Pry out luggage compartment liner retaining clips and peel back liner to gain access to upper shock absorber mounting nuts . See Fig. 3.

0013220

Fig. 4. Support rear trailing arm from below before removing upper or lower (arrow) shock mounting .

6. Transfer shock top mounting plate, dust coverand related components to new shock absorber . See Fig. 5. ' Protective cap

Upper mounting nut 14 Nm (10 ft-Ib)

1120 Shock upper mount ,~,--~to body nuts (renew) - ' ~ 24 Nm (17 ft-Ib) -Gasket (renew) pper mount

I I

I 1

I I

Rear shock absorber

I II

---spacer 0013224

Fig. 3. Rear shock upper mounting nuts (arrows) in luggage compartment . Liner has been peeled back. NOTEOn convertible models, the upper shock absorber mount is in the convertible top compartment behind the rear seat.

Rubber bumper

Dust shield

4. Support trailing arm from below using a transmission jack or equivalent . See Fig. 4. Remove shock absorber upper mounting nuts. CAUTIONThe shock absorber prevenís the drive axle and trailing arm from drooping too far, so always support the trailing arm before removing the shock. Damage to drive axle CVjoints can result.

Lower mounting bolt 77 Nm (57 ft-Ib)

1 I 0013236

Fig. 5. Rear shock absorber assembly.

5. While supporting shock absorber, carefully remove lower mounting bolt. Lower shock absorber out of wheel well . SHOCKABSORBERS AND SPRINGS

330-4

REAR SUSPENSION

7. Installation is reverse of removal, noting the following: " Make sure all threaded bolts, nuts and makng surfaces are clean. " Instan shock absorber finto shock tower using a new upper mounting gasket and new self-locking nuts . " Tighten lower bolt to its final torque once car is on ground . Tightening Torques " Road wheel to hub . . . . . . . . . 100±10 Nm (74±7 ft-Ib) " Shock absorber to trailing arm (car in normal loaded position) . . . . . . 77 Nm (57 ft-Ib) " Shock absorber to upper mount . . . . . 14 Nm (10 ft-Ib) " Shock absorber upper mount to body (M8 self-locking nuts) . . . . . . . . . . . . . 24 Nm (17 ft-Ib)

Coil spring, removing and installing

Fig. 6. Drive axle to final drive mounting bolts (arrows) .

0012103

WARNING " The coil spring is under compressive force and ís extremely dangerous until compression is removed.

7. If spring is to be reused, carefully inspect it for any surface damage or corrosion. Inspect spring mounts for any signs of damage . Replace any parts showing evidence of wear or damage .

" lt is recommended that a restraining chain be installed between the bottom of the coil spring and the upper control arm to retain the spring in case of accidental release. Personal injury can result if the compressed coil spring is not released slowly and carefully.

8. Fit coil spring to spring mounts and insta¡¡ restraíning chaina

" Make sure that the car is firmly supported on jack stands designed for the purpose . Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts .

1 . Raise car and remove rear wheel. 2. Support suspension arm from below using a transmission jack or equívalent. 3. Remove drive axle from final drive. See Fig. 6. Suspend drive axle from chassis using stiff wire . 4. Disconnect shock absorber from traíling arm . 5. Lower suspension slowly and carefully until the compressed coil spring is fully unloaded . CAUTION -

The shock absorber prevents the drive axle and trailíng arm from drooping too far, so always support the trailing arm before removing the shock. Damage to drive axle CVjoints can result.

6. Remove restraining chain and remove coi¡ spring .

9. Slowly lift suspension back into position, making sure coil spring is correctly seated in upper and lower coil spring mounts . 10 . When suspension has been lifted sufficiently, instan shock absorber to trailing arm. Remove restraining chain. 11 . The remainder of installation is reverse of removal. Tightening Torques " Drive axle to final drive flange M8 Torx bolt . . . . . . . . . . . . . . . . . . . . 64 Nm (47 ft-Ib) M10 Torx bolt . . . . . . . . . . . . . . . . . . . 83 Nm (62 ft-Ib) " Road wheel to hub . . . . . . . . . 100±10 Nm (74±7 ft-Ib) " Shock absorber to trailing arm . . . . . . 77 Nm (57 ft-Ib)

REAR WHEEL BEARINGS The rear wheel bearing is a unitized assembly and is not repairable separately. See Fig. 7. Special press tools, to be used with the trailing arm attached to the car, are required to replace the wheel bearings . Read the procedure through before beginning the job.

REAR WHEEL BEARINGS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

REAR SUSPENSION Circlip

Drive flange

330-5

Collar nut

Wheel bearing 0012152

Fig. 7. Rear wheel bearing assembly.

0013125

Rear wheel bearing, replacing 1 . Raise car and support safely. Remove rear wheel .

Fig. 9. Drive flange being removed from bearing assembly using impact style puller.

2. Remove drive axle as described later.

6. Remove bearíng retainer circlip from trailing arm.

3. Remove brake caliper assembly and rotor as described in 340 Brakes. Leave brake hose connected to caliper. Suspend caliper assembly from chassís using stiff wire .

7. Using appropriate press tools, pull bearing assembly out of trailing arm bearing housing .

4. Remove ABS pulse sensor. See Fig. 8.

8. Inspect bearing housing for any damage or contamina tion . Clean housing bore thoroughly before installing new bearing. Make sure al¡ thread bores, bolts, nuts and mating surfaces are clean 9. Install new bearing assembly using press tools. Apply force only to outer race when installing bearing. WARNING M3 installation: red sealing ríng on rear wheel bearing must face outward. Otherwíse ABS will not func-

tion .

10 . Insta¡¡ new circlip . The old circlip should never be reused . CAUTIONMake sure that the bearing is pressed in far enough to contact the shoulder at the back side of the housing and that the circlip is fully seated in its

groove .

Fig. 8. ABS pulse sensor being removed.

0013223

5. Remove drive flange from bearing assembly. See Fig. 9. NOTEIf the inner bearing race remains attached to the drive flange, use BMW special tool nos . 00 7 500 and 33 1 312 or equivalents to separate inner race from flange.

11 . Draw drive flange into bearing using appropriate press tools. Support bearing inner race when pressing in drive flange . NOTEBMW specifies special tools to pull the drive fiange through the wheel bearing into position. If using alternative tools, be sure to support the bearing inner race when pressing or pulling the drive flange finto place.

REAR WHEEL BEARINGS

330-6

REAR SUSPENSION

12 . Install brake caliper assembly and rotor as described in 340 Brakes . 13 . Install drive axie as described below. Tightening Torques " Brake rotor to drive flange . . . . . . . . . 16 Nm (12 ft-ib) " Brake caliper to trailing arm . . . . . . . . 67 Nm (50 ft-Ib) " Drive axie collar nut to drive flange . . . . . . . . . . . . . . . . . . . 250 Nm (184 ft-Ib) M3 . . . . . . . . . . . . . . . . . . . . . . . . . 300 Nm (221 ft-Ib) " Road wheel to hub . . . . . . . . . 100±10 Nm (74±7 ft-Ib)

WARNING Make sure that the car is firmly supported on jack stands designed for the purpose . Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.

2. Pry off dust cap from center of wheel hub. 3. Remount wheel and lug boits. 4. Lower car to ground . With an assistant applying brakes, loosen collar nut. Do not remove completely. See Fig . 11 . The drive flange collar nut is tightened to a torque of 250 Nm (184 ft-Ib) . Make sure the car is firmly on the ground.

DRIVE AXLES The drive axles use constant-velocity (CV) joints on both ends . To replace a CV joint or dust boot, the drive axie must be removed from the car. The components of the drive axie are illustrated in Fig. 10 .

Drive axie, removing and installing 1 . Raise rear of car. Remove rear wheel .

5. Raise car and remove wheel. 6. Remove brake caliper assembly and rotor as described in 340 Brakes. Leave brake hose connected to caliper. Suspend caliper assembly from chassis using stiff wire . 7. Remove drive axie from drive flange . See Fig. 12 . Suspend drive axie from chassis using stiff wire.

Dust cover Drive axle Outer CV joint

-Reinforcement

Outer CV boot kit

Inner CV boot kit

Fig. 10 . Drive axie assembly. DRIVEAXLES

REAR SUSPENSION

330-7

9. Lower trailing arm sufficiently to gain clearance for removing drive axle . If necessary use an appropriate puller to Rmove drive axle from wheel bearing housing. See Fig. 13 .

Fig. 11 . Drive flange collar nut (arrow).

0012111

Fig. 13. Press drive axle from wheel bearing housing using puller. 10 . Installation is reverse of removal.

" Apply a light coating of oil to contact face of collar nut, and install it loosely. " Install road wheel and lower car to ground . " With an assistant applying brakes, tighten drive axle collar nut to its final torque . " Install a new collar nut retaining plate.

Fig. 12 . Drive axle to final drive mounting bolts (arrows) .

0012103

Tightening Torques " Brake caliper to trailing arm . . . . . . . . 67 Nm (50 ft-Ib) " Brake rotor to drive flange . . . . . . . . . 16 Nm (12 ft-Ib) " Drive axle collar nut to drive flange . . . . . . . . . . . . . . . . . . . 250 Nm (184 ft-Ib) M3 . . . . . . . . . . . . . . . . . . . . . . . . . 300 Nm (221 ft-Ib) " Drive axie to final drive unit mounting flange . . . . . . . . M8 Torx bolt . . . . . . . . . . . . . . . . . . . . 64 Nm (47 ft-Ib) M10 Torx bolt . . . . . . . . . . . . . . . . . . 100 Nm (74 ft-Ib) Road wheel to hub100±10 Nm (74t7 ft-Ib) " Shock absorber to trailing arm . . . . . . . . . . . . . . . . . . . . . 77 Nm (57 ft-Ib)

8. Support trailing arm from below, using a transmission jack or equivalent . Remove shock absorber to trailing arm bolt . WARNING It is recommended that a restraining chain be installed between the bottom coil of the coil spring and the upper control arm to retain the spring in case of accidental release. Personal injury can result if the compressed coil spring is not released slowly and carefully.

DRIVEAXLES

330-8

REAR SUSPENSION

CV boot, replacing

CV joint

NOTE" The outer CV joint cannot be removed from the axle shaft. In order to replace the outer CV boot, it is necessary to remove the inner joint and boot first.

111L -0,1,1 "IC OYA

" If the CV joints are worn or defective, a complete rebuilt axle shaft is available from an authorized BMW dealerparts department. 1 . Remove drive axle from car as described above .

Drive axle-"

e:>, )

0006560

2 . Remove inner and outer CV boot clamping bands and cut old boots off joints and shaft . Clean grease from joints .

Fig . 15. Support CV joint at inner hub during pressing operation (arrows) .

3. Lift off dust cover from inner CV joint and remove circlip retaining joint inner hub to axle shaft . See Fig . 14 .

5 . Clean all old lubricantoff shaft splines and inner joint's splines . NOTETo inspect a CV joint, clean away the grease and look for galling, pittihg and other signs of wear or physical damage. Polished surfaces or visible ball tracks alone are not necessarily cause for replacement. Discoloration due to overheating indicates lack of lubrication . 6 . Place new clamping bands and CV boots over drive axle . NOTEWhen replacing CV joint boots, use complete CV joint boot repair kits. A kit will include a new boot, clamping bands, special lubricant, and a new inner CV joint circlip. The kit is available from an authorized BMW dealer parts department. 7 . Apply Loctite® 270 or an equívalent heavy-duty lockíng compound to drive axle splines . Position new CV joint on shaft so that raised or taller side of hub is facing shaft.

Fig . 14 . Dust cover shown removed from inner CV joint . Clean away grease and remove circlip (arrow) from shaft end . 4 . While supporting inner hub, press axle shaft out of joint . See Fig . 15 .

WARNING Do not let the locking compound contact the balls in the joint. Apply only a thin coat to cover the splines. 8 . While supporting axle shaft, press inner hub of CV joint onto shaft. Install new circlip . NOTEDo not let the ball hub pivot more than 20° in the outer ring of the joint. The halls will fall out if the hub ís pivoted too far.

DRIVE AXLES

REAR SUSPENSION 9. Pack each CV joint and rubber boot with specified amount of lubricant supplied . Apply adhesive to large end of boot and mount it on joint. Secure boot with clamps . Apply sealer to inner CV joint dust cover and instan . NOTE-

" Before installing each small boot clamp be sure to "burp" the boot by flexing the CV joint as far over as it will go. A small screw-driver inserted between the boot and the axle-shaft will help the process . " BMW recommends Bostil101513 or EppleC4851 adhesive, and Epple®39 or Curil©T sealer

CV Joint Lubricant Capacity " Wheel hub end ex . M3 . . . . . . . . . . . . . . . . . . . . . . . 80 gram (2 .8 oz.) M3 . . . . . . . . . . . . . . . . . . . . . . . . . 100 gram (3 .5 oz.) " Final drive end . . . . . . . . . . . . . . . . . 85 gram (3 .0 oz.)

330-9

REAR SUSPENSION ARMS The trailing arms, control arms and their mounting bushings control the position of the rear wheels . A damaged suspension arm or worn bushings will change the rear wheel align ment and may adversely affect handling and stability. WARNING Do notattempt to straighten a damaged suspension arm. Bending or heating may weaken the original part. If the suspension arm shows any signs of damage or excessive corrosion, it must be replaced.

If the rear brake cine is disconnected to remove a trailing arm, the complete braking system must be bled as part of the installation procedure . When performing repairs to rear suspension components, refer to Fig. 16 .

10 . Install drive axle as described earlier.

1 . Final drive carrier 2. Stabilizer bar 3. Upper control arm 4. Lower control arm 5. Trailing arm 6. Trailing arm front bracket

0013112

Fig. 16. Rear trailing arms, control arms and final drive carrier. REAR SUSPENSION ARMS

330-1 0

REAR SUSPENSION

Trailing arm, removing and installing 1 . Raise rear end of car and remove wheel. WARNING -

Make sure that the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.

2. Remove drive axle as described earlier. 3 . Remove brake rotor and caliper as described in 340 Brakes . Do not remove brake line from caliper. Hang caliper from body with wire . 4. Remove parking brake cable from brake shoe expander . See 340 Brakes . 5. Remove rear brake line bracket from trailing arm. See Fig. 17 .

0013220

Fig. 18. Support trailing arm before removing lower shock bolt (arrow) . 8. Unbolt upper and lower control arms from trailing arm, as described later. 9. Remove ABS wheel speed sensor from rear wheel bearing housing . Unclip sensor wiríng from trailing arm. If removing right trailing arm, separate brake pad wear sensor connector. See Fig. 19 .

Fig. 17. Brake line bracket bolts on trailing arm (arrow). 6. Support trailing arm from below with a transmission jack or equivalent . WARNING -

It is recommended that a restraining chain be installed between the bottom coil of the coil spring and the upper control arm to retain the spring in case of accidental release. Personal injury can result if the compressed coil spring is not released slow1y and carefully.

7. Remove shock absorber to trailing arm bolt . See Fig. 18 . Slowly lower suspension until coil spring can be safely removed. REAR SUSPENSION ARMS

0012104

Fig. 19 . Brake pad wear sensor and ABS wheel speed sensor connectors (arrow). 10 . Remove three bolts holding trailing arm front bracket to body. See Fig . 20 . Remove trailing arm .

REAR SUSPENSION

330- 1 1

Trailing arm bushing, replacing NOTEWhen replacing any bushing in the rear trailing arm, measure and record the orientation and protrusion of the bushing from its boss. Press in new bushing to match the position of the old one.

1 . Remove trailing arm as described above . 2. Press bushing out of trailing arm using appropriate press tools . 3. Coat new bushing with Circolight9 lubricant or equivalent . 4. Using appropriate press tools, draw new bushing into trailing arm until previously measured protrusion is achieved . Fig. 20 . Trailing arm front bracket bolts (arrows) .

0013222

11 . If trailing arm is being replaced, transfer trailing arm front bracket. Transfer attached brake system components to new arm as described in 340 Brakes . Insta¡¡ a new wheel bearing as described earlier under Rear Wheel Bearings .

5. If front bracket bushing was replaced, align front bracket before tightening bolt . See Fig. 21 .

NOTEBMW-supplied replacement trailing arms come with the bushings installed. A new wheel bearing will have to be installed.

12 . Installation is reverse of removal. " Always use new self-locking nuts . " Have car professionally aligned when job is complete . Tightening Torques " Drive axle #o final drive unit mounting flange M8 Torx bolt . . . . . . . . . . . . . . . . . . . . 64 Nm (47 ft-Ib) M10 Torx bolt . . . . . . . . . . . . . . . . . . 100 Nm (74 ft-Ib) " Road wheel to wheel hub . . . . 100±10 Nm (74t7 ft-Ib) " Shock absorber to trailing arm . . . . . . 77 Nm (57 ft-Ib) " Trailing arm to front bracket . . . . . . . 110 Nm (81 ft-Ib) " Trailing arm bracket to body . . . . . . . . 77 Nm (57 ft-Ib) " Trailing arm to upper or lower control arm (M12 bolt) . . . . 110 Nm (81 ft-Ib)

B=8mm

measured up from casting mark on trailing arm.

0013237

Fig. 21 . When installing trailing arm front bracketuising 8mm bar stock. 6. Installation is reverse of removal.

" Have car professionally aligned when job is complete .

Tightening Torques " Trailing arm to front bracket . . . . . . . 110 Nm (81 ft-Ib) " Trailing arm bracket to body . . . . . . . . 77 Nm (57 ft-Ib)

REAR SUSPENSION ARMS

330- 1 2

REAR SUSPENSION

Upper control arm, removing and installing 1 . Raise rear end of car and remove wheel. WARNING Make sure that the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.

2. Remove drive axle as described earlier. 3. Remove stabilizer bar link from upper control arm. 4. Support trailing arm from below with a transmission jack or equivalent . WARNING It is recommended that a retaining chain be installed between the bottom coil of the coil spring and the upper control arm to retain the spring in case of accidental release . Personal injury can result if the compressed coil spring ís not released slowly and carefully.

5. Remove lower shock absorber bolt. Refer to Fig. 18 . Slowly lower trailing arm until coil spring is fully released . Remove restraining chain and remove spring . 6. Remove both upper control arm mounting bolts. Remove control arm. 7. Installation is reverse of removal .

" Always use new self-locking nuts . " Have car professionally aligned when job is complete . " Insta¡¡ drive axle as described earlier.

Tightening Torques " Drive axle to final drive flange M8 Torx bolt . . . . . . . . . . . . . . . . . . . 64 Nm (47 ft-Ib) M10 Torx bolt . . . . . . . . . . . . . . . . . 100 Nm (74 ft-Ib) " Shock absorber to trailing arm . . . . . . 77 Nm (57 ft-Ib) " Upper control arm to final drive carrier (M12 bolt) . . . . . . 77 Nm (57 ft-Ib) " Upper control arm to trailing arm (M12 bolt) . . . . . . . . . 110 Nm (81 ft-Ib)

Lower control arm, removing and installing 1 . Raise rear end of car and support it securely on jackstands . Remove rear wheel .

3. Use a soft hammer to tap control arm out of its mounting points . 4. Installation is reverse of removal. NOTEUse a new bolt and washer assembly at the final drive carrier mountíng point for the control arm.

Tightening Torque " Lower control arm to final drive carrier (M12 bolt) . . . . . . 77 Nm (57 ft-Ib) " Lower control arm to trailing arm (M12 bolt) . . . . . . . . . 110 Nm (81 ft-Ib)

FINAL DRIVE CARRIER Final drive carrier, removing and installing

1 . Raise rear end of car and support it securely on jack stands . Remove rear wheels .

2. Remove driveshaft . See 260 Driveshaft . 3. Remove both drive axles as described earlier. 4. Disconnect stabilizer bar from upper control arms. Remove stabilizer bar mounts . 5. Disconnect speedometer harness connector on final drive (where applicable) . 6. Remove rear section of exhaust system . See 180 Exhaust System . NOTEIt may be easier to remove complete exhaust as one piece. See 180 Exhaust System .

7. Remove upper and lower control arms as described earlier. 8. Support final drive carrier with transmissíon jack . Remove mounting bolts and nuts at final drive carrier bushing mounts . See Fig. 22 . 9. Slowly lower final drive and final drive carrier, detaching wire harness and connectors as necessary. 10 . Final drive may now be unbolted from final drive carrier.

2. Remove both lower control arm mounting bolts.

FINAL DRIVE CARRIER

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

Fig. 22. Final drive carrier mounts (arrows) .

uu1J221

11 . Installation is reverse of removal. " Check and adjust parking brake as described in 340 Brakes . " Always use new self-locking fasteners. " Have car professionally aligned when job is complete . Tightening Torques " Drive axle to final drive flange M8 Torx bolt . . . . . . . . . . . . . . . . . . . 64 Nm (47 ft-Ib) M10 Torx bolt . . . . . . . . . . . . . . . . . 100 Nm (74 ft-Ib) " Driveshaft to final drive flange . . . See 260 Driveshaft " Final drive carrier to body . . . . . . . . . 77 Nm (57 ft-Ib) " Final drive to final drive carrier (M12 bolts) Front mount . . . . . . . . . . . . . . . . . . . . 95 Nm (70 ft-lb) Rear mounts . . . . . . . . . . . . . . . . . . . 77 Nm (57 ft-Ib) " Road wheel to wheel hub . . . . 100±10 Nm (74t7 ft-Ib) " Upper or lower control arm to final drive carrier (M12 bolts) . . . . . 77 Nm (57 ft-Ib)

FINAL DRIVE

331-1

331 Final Drive GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331-1 FINAL DRIVE SERVICE . . . . . . . . . . . . . . . . 331-1 Final drive oí¡, draining and filling . . . . . . . . . . 331-1

Final Drive Oil Seals . . . . . . . . . . . . . . . . . . . . 331-1 Final drive flange oil sea¡, replacing . . . . . . . . . 331-2 Final drive input shaft oil seal, replacing . . . . . 331-3 Final drive unit, removíng and installing . . . . . . 331-3

GENERAL

This repa¡r group covers repair operations that do not require complicated disassembly of the final drive. Internal repairs and final drive disassembly are not covered in this manual .

FINAL DRIVE SERVICE Al¡ final drive work requires some method of raising the car and supporting it securely while the work is performed. Jack stands and a floor jack can easily be used, but use extreme caution when working beneath the car. See 010 Fundamentais for the Do-It-Yourself Owner. NOTE-

Removal of final drive carrier is covered in 330 Rear

Suspension .

0013113

Fig. 1 . Final drive drain plug (A) and fill plug (B). NOTE-

The final drive fluid level is correct when the fluid begins to spill from the fill plug .

Final drive oil, draining and filling 1 . Drive car to warm final drive fluid. 2. Raise car and support safely. WARNING -

Make sure that the car is firmly supported on jack stands designed for the purpose . Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.

3 . Place a drain pail below final drive and remove drain and fill plug from final drive. See Fig. 1 . NOTE-

" Use a 14 mm alíen bit socket to remove the drain plug. Alternatively, cut approximately 30 mm (1 .2 in) from an alíen key and use a box end wrench on the key stub .

4. Install and tighten drain plug . 5. Fill final drive with appropriate type and quantity of lubricant. Insta¡¡ and tighten fill plug .

Final Drive Drain and Fill " Oil specifications w/o limited slip . . . . . . . . BMW SAF-XO Synthetic Oil with limited slip . . . . . . . BMW SAF-XIS Synthetic Oil " Final drive oil capacity 4-cylinder . . . . . . . . . . . . . . . . . . . . . . 1 .1 liters (1 .2 qt) 6-cylinder . . . . . . . . . . . . . . . . . . . . . . 1 .7 liters (1 .8 qt)

Final Drive Oil Seals Low oil level caused by faulty oil seals may be the cause of noisy final drive operation or limited-slip chatter. The drive flange (side) and input shaft (front) oil seals can be replaced while the final drive is installed. NOTE-

Do not mistake leaking CV joints for flange seal leaks. It may be helpful to degrease the final drive to pinpoint the source of the leak prior to replacing seals.

FINAL DRIVE SERVICE

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331-2

FINAL DRIVE

Tjack " :.- :. n

Make sure that the car is firm1y supported on

. .-

2. Detach drive axle(s) from final drive. See 330 Rear Suspension . CA UTIONSuspend the detached drive axle from the car body with a stiff wire hook to prevent damage to the outer CV joint.

3. Pry drive flange from final drive. See Fig. 2.

B315

Fig. 3. Drive flange snap ring (arrow) to be removed from final drive housing. 5. Pry old oil sea¡ from its recess using a hooked seal removal tool, or a large screwdriver. Use pan to catch draining fluid. CA UTIONBe careful not to mar the final drive housing when removing the sea¡.

6. Dip new seal in final drive lubricant and drive seal into place until fully seated . 7. Insta¡¡ new snap ring in groove of final drive housing. Make sure both ends of ring are fully seated in groove . 8. Insta¡¡ drive flange by pressing it in by hand until snap ring engages. It may be necessary to turn drive flange slightly while pushing. Fig. 2. Drive flange being pried off. For leverage, use a wooden dowel as shown . 4. Remove wire (snap) ring from final drive opening. See Fig. 3. NOTEInspect flange at the point where the oil seal rides on the shaft. Replace the flange assembly if there is a groove worn in the shaft

FINAL DRIVE SERVICE

9. Attach drive axle and tighten bolts. 10 . Top off final drive with ofl . Tightening Torque " Drive axle to final drive flange M8 Torx bolt . . . . . . . . . . . . . . . . . . . . 64 Nm (47 ft-Ib) M10 Torx bolt . . . . . . . . . . . . . . . . . . 100 Nm (74 ft-Ib)

FINAL DRIVE Final drive input shaft oil sea¡, replacing 1 . Raise car and support safely. 2. Drain final drive oil as described earlier. 3. Remove driveshaft from final drive input shaft flange . See 260 Driveshaft . 4. Make matching marks on input shaft and input shaft collar nut. See Fig . 4.

331-3

Tightening Torques " Final drive input shaft flange to pinion with 4 bolt side covers . . . . . . . . . . 175 Nm (129 ft-Ib) (or until match marks line up) " Final drive input shaft flange to pinion with 6 bolt side covers . . . . . . . . . . . 185 Nm (137 ft-Ib) (or until match marks line up) CA UTION-

If the input flange nut torque is exceeded, or the nut is tightened past the marks, the crushable collar sleeve behind the flange will need to be replaced. This operation requires disassembly of the final drive unit.

10 . Install a new lockplate and refill final drive with lubricant . 11 . Remaining assembly is reverse of disassembly. Tightening Torques " Driveshaft to final dríve flange . . . See 260 Driveshaft " Flex-disc to driveshaft or transmission flange . . . . . . . . . . . See 260 Driveshaft " Final drive drain and fill plugs . . . . . . . 70 Nm (52 ft-Ib) Fig . 4.

Make matching marks on input shaft collar nut and flange .

5. Pry lockplate from nut. Hold input flange and remove collar nut. If necessary, use a puller to remove input flange . 6. Remove final drive front dust cover. 7. Pry faulty sea¡ from its recess using a hooked sea¡ removal tool or a large screwdriver. Dip new sea¡ in final drive lubricant and drive it into position . CAUTION -

ee careful not to mar the housing when removing the seas.

8. Install new final drive front dust cover . 9. Lightly lubricate input shaft and press input flange back on . Insta¡¡ collar nut and slowly tighten until matching marks line up, coming as close as possible to specified torque .

Final drive unit, removing and installing 1 . Raise rear end of car and support it securely on jack stands . Remove rear wheels . 2. Remove driveshaft from final drive input flange. See 260 Driveshaft. 3. Remove both drive axles from final drive unit . Suspend axle using stiff wire . See 330 Rear Suspension . 4. Disconnect stabilizer bar from upper control arms . Remove left and right stabilizer bar mounts . 5. Disconnect speedometer harness connector on final drive (where applicable) . 6. Support final drive with transmission jack. Remove mounting bolts at front and rear. See Fig. 5. 7. Slowly lower final drive unit and remove towards rear.

FINAL DRIVE SERVICE

331- 4

FINAL DRIVE 8. Installation is reverse of removal.

" Check and adjust parking brake as described in 340 Brakes . " Always use new self-locking fasteners. " Have car professionally aligned when job is complete .

0013242

0013243

Fig. 5. Final drive to final drive carrier rear (A) and front mounting bolts (B).

FINAL DRIVE SERVICE

Tightening Torques " Drive axle to final drive flange M8 Torx bolt . . . . . . . . . . . . . . . . . . . . 64 Nm (47 ft-Ib) M10 Torx bolt . . . . . . . . . . . . . . . . . . 100 Nm (74 ft-Ib) " Driveshaft to final drive flange . . . See 260 Driveshaft " Final drive carrier to body . . . . . . . . . . 77 Nm (57 ft-Ib) " Final drive to final drive carrier (M12 bolts) Front mount . . . . . . . . . . . . . . . . . . . . 95 Nm (70 ft-Ib) Rear mounts . . . . . . . . . . . . . . . . . . . . 77 Nm (57 ft-Ib) " Road wheel to wheel hub . . . . 100±10 Nm (74±7 ft-Ib) " Upper or lower control arm to final drive carrier (M12 bolts) . . . . . 77 Nm (57 ft-Ib))

BRAKES

340-1

340 Brakes GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340-1 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 340-1 BLEEDING BRAKES . . . . . . . . . . . . . . . . . . 340-3 Pressure bleeding brakes (except cars with AST) . . . . . . . . . . . . . . . . .340-3 BRAKE PADS, CALIPERS, AND ROTORS . . . . . . . . . . . . . . . . . . . . . . . . . 340-3 Brake pads, replacing . . . . . . . . . . . . . . . . . . . 340-4 Brake caliper, removing and installing . . . . . . 340-6 Brake rotor, removing and installing . . . . . . . . 340-7 MASTER CYLINDER . . . . . . . . . . . . . . . . . . .340-7 Master cylinder, removing and installing . . . . . 340-7

GENERAL

BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . 340-8 Brake booster, removing and installing . . . . . . 340-8 PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . 340-10 Parking brake, adjusting . . . . . . . . . . . . . . . . 340-10 Parking brake shoes, removing and installing . 340-11 Parking Brake cable, replacing . . . . . . . . . . . . 340-11 ANTILOCK BRAKE SYSTEM (ABS) . . . .340-11 ABS System Inspection . . . . . . . . . . . . . . . . . 340-12 ABS wheel speed sensors, replacing . . . . . . 340-12 TABLES a. Brake System Troubleshooting . . . . . . . . . . . . . . . .340-2 b. Brake Rotor Reconditioning Specifications . . . . . . .340-7

TROUBLESHOOTING

WARNING " Although semi-metallic and metallic Brake friction materials in Brake pads or shoes no longer contain asbestos, they produce dangerous dust.

Brake performance 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 .

" Brake fluid is poisonous, highly corrosive and dangerous to the environment Wear safety glasses and rubber gloves when working with Brake fluid. Do not siphon Brake fluid with your mouth. Immediately clean away any fluid spilled on painted surfaces and wash with water, as Brake fluid will remove paint.

Air in the Brake fluid will make the Brake pedal feel spongy during braking or will increase the Brake pedal force required to stop . Fluid contaminated by moisture or dirt can corrode the system . Inspect the Brake fluid inside the reservoir. If it is dirty or murky, or is over a year old, the fluid should be replaced .

" Always use new Brake fluid from a fresh, unopened container. Brake fluid will absorb moisture from the air. This can lead to corrosion problems in the braking system, and will also lower the Brake fluid's boiling point. Dispose of Brake fluid properly. " Do not reuse self-locking nuts, bolts or fasteners. They are designed to be used only once and may fail if reused. Always replace them with new selflocking fasteners.

BMW E36 models are equipped with vacuum power-assisted four-wheel disc brakes with an integral Antilock Brake System (ABS). Single-piston calipers act on solid or vented front rotors and solid rear rotors . A brake pad wear sensor for each axle indicates when brake pads need replacement . The dual drum-type parking brake system is integrated with the rear brake rotors . NOTEM3 models have vented directional Brake rotors on the rear axle as well as on the front.

Visually check the hydraulic system starting at the master cylinder. To check the function of the master cylinder hold the brake pedal down hard with the engine running. The pedal should feel solid 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 can be found, the master cylinder is faulty and should be replaced . Checkall Brake fluid lines and couplings for leaks, kinks, chafing and corrosion . Check the Brake booster by pumping the Brake pedal approximately 10 times with the engine off. Hold the pedal down and startthe engine. The pedal should fa¡¡ slightly. If not, check for any visible faults 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 by worn suspension components .

TROUBLESHOOTING

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340-2

BRAKES

When troubleshooting, keep in mind that tire inflation, wear and temperature can affect braking and suspension . See 310 Front Suspension for more information on front suspension parts inspection . Table a lists symptoms of brake problems, their probable causes, and suggested corrective actions .

Table a. Brake System Troubleshooting Brake squeal

Symptom

Pedal goes to floor when braking Low pedal after system bleeding Pedal spongy or brakes work only when pedal is pumped Excessive braking effort

Probable cause a . Incorrectly installed brake pads or parking brake shoes b . Brake pad carriers dirty or corroded c . Brake pad anti-rattle springs faulty or missing d . Brake pads heat-glazed or oil-soaked e . Wheel bearings worn (noise most pronounced when turning) a . Brake fluid leve¡ low due to system leaks b . Master cylinder faulty 1 a. Master cylinder faulty a. Air in brake fluid b . Master cylinder faulty (interna¡ return spring weak) c . Leaking line or hose unions a. Brake pads wet b. Brake pads heat-glazed or oil-soaked c . Vacuum booster or vacuum hose connections to booster faulty

Brakes pulsate, chatter or grab

a . Warped brake rotors b. Brake pads worn c . Brake pads heat-glazed or oil-soaked

Uneven braking, car pulís to one side, rear brakes lock

a . Incorrect tire pressures or worn tires

Brakes drag, bind or overheat

( a . Brake caliper or brake pads binding b . Master cylinder faulty

b. Brake pads on one side of car heatglazed or oil-soaked c . Caliper or brake pads binding d . Worn suspension components

WARNING On cars with All Season Traction (AST), special BMW service equipment is required to properly bleed the ABS/AST system. For safety reasons, the brake system on cars with ABS/AST must not be bled using the procedures described in this repair group.

BLEEDING BRAKES Brake bleeding is usually done for one of two reasons : Either to replace oíd brake fluid as part of routine maintenance or to expel trapped air in the system that resulted from opening the brake hydraulic system during repairs.

Repairs

a . Check component installation .

b . Remove brake pads and clean calipers. c. Install/replace anti-rattle springs . d . Replace brake pads . Clean rotors . Replace leaking calipers as required . e . Replace worn bearings . See 310 Front Suspension or 330 Rear Suspension . a . Check fluid level and inspect hydraulic system for signs of leakage . Fill and bleed system . I b . Replace master cylinder. 1 a . Replace master cylinder. a. Bleed system . b . Replace master cylinder. c . Repair or replace lines and hoses . Bleed system. a. Use light pedal pressure to dry pads while driving . b . Replace brake pads . Clean rotors. Replace leaking calipers. c . Inspect vacuum lines. Test vacuum booster and re place as required . Test vacuum non-return valve for one-way air flow . a. Resurface or replace rotors . b. Replace brake pads . c . Replace brake pads . Clean rotors . Replace leaking calipers . a. Inspect tire condition . Check and correct tire pressures . b. Replace brake pads . Clean rotors. Replace leaking calipers . c . Clean and recondition brakes . d. Inspect for worn or damaged suspension components . See 310 Front Suspension or 330 Rear Suspension . a . Clean or replace caliper . b. Replace master cylinder.

Always use new brake fluid from an unopened container. It

is important to bleed the entire system when any part of the

hydraulic system has been opened . On cars not equipped with traction control (AST), brake system bleeding should be done with a pressure bleeder . On cars with AST, brake bleeding should be done by an authorized BMW dealer . WARNING On cars with All Season Traction (AST), special BMW service equipment is requíred to properly bleed the ABS/AST system. For safety reasons, the brake system on cars with ABS/AST must not be bled using the procedures described in thís repair group.

BLEEDING BRAKES

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BRAKES When bleeding the brakes, start at the wheel farthest from the master cylinder and progress in the following order: " right rear brake " left rear brake " right front brake " left front brake

340-3

4. Close bleeder screw and release brake pedal. Refill brake fluid reservoir and proceed to rear left wheel. 5. Proceed with the remaining wheels using the order listed earlier.

Pressure bleeding brakes (except cars with AST) 1 . Top off brake fluid in reservoir and connect pressure bleeder to reservoir. Connect bleeder hose and bottle to right rear caliper bleeder screw. Pressurize system to approximately 1 bar (14.5 psi) .

Tightening Torques " Bleeder screws : 7 mm screw . . . . . . . . . . . . . . . . . . . . . . 5 Nm (4 ft-Ib) 9 mm screw . . . . . . . . . . . . . . . . . . . . . . 6 Nm (5 ft-Ib)

BRAKE PADS, CALIPERS, AND ROTORS The E36 front brake caliper is shown in Fig. 2. The rear brake caliper is shown in Fig. 7.

CAUTIONDo not exceed a pressure of 2 bar (29 psi) when pressure bleeding the brake system. Excessive pressure will damage the brake fluid reservoir.

2. Have a helper hold brake pedal down . 3. Open bleeder screw. See Fig 1 . Have helper slowly , pump brakes about 10 times with bleeder screw open, holding pedal down on the last pump. When escaping fluid is free of air bubbles, close bleeder screw. CAUTIONBleeder hose must always remain submersed in the clean brake fluid whenever the bleeder valve is open .

Brake pads can be replaced without disconnecting the brake fluid hose from the caliper or having to bleed the brakes . The rotors can be replaced without disassembling the wheel hub and bearing. Always machine or replace rotors in parts. Replace pads in sets . WARNING" Althoughsemi-metallicandmetallicbrake friction materials in brake pads or shoes no longer con tain asbestos, they produce dangerous dust. " Treat all brake dust as a hazardous material. " Do not create dust by grinding, sanding, or cleaning brake friction surfaces with compressed air. " Breathing any brake dust can cause serious diseases such as cancer, and may result in death.

Brake pads, replacing This procedure is applicable lo both front and rear brakes . Front and rear brake assemblies are basically the same, except that the rear brake rotors house the parking brake mechanism 1 . Raise car and remove wheels . WARNING Make sure the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.

2. Remove plastic caps from guide bolts and then remove guide bolts. See Fig. 3. Fig. 1. Brake caliper bleeder screw (arrow) .

0012113

3. If applicable, disconnect brake pad wear sensor connector and remove wiring from its holder. 4. Remove anti-rattle clip from caliper. See Fig. 4. BRAKE PADS, CALIPERS, AND ROTORS

340-4

BRAKES Bleeder valve and dust cap

Brake pad wearsensor (left wheel only)

- Brake pad . carrier ^_

Mounting bolt

Anti-rattle spring-

0012154

Fig. 2. Front brake caliper assembly.

Fig. 3. Brake caliper guide bolts (arrows) . 5. Pull caliper straight off rotor. CAUTIONDo not let the brake cafiper hang from the brake hose. Suspend ft from the chassis using stiffwire .

BRAKE PADS, CALIPERS, AND ROTORS

0012155

Fig. 4. Removing anti-rattle clip by unhooking at top and bottom . Use screwdriver as an aid (arrow). NOTEIf there is a ridge on the rotor edge, the cafiperpfston will have to be pushed back finto the cafiper before the cafiper can be removed.

BRAKES

340-5

6. Remove brake pads from caliper. Where applicable, carefully pry pad wear sensor from pad. See Fig. 5.

0012157

Fig. 6. Brake caliper piston being pressed into caliper to make room for new pads . Use a rag to protect caliper piston and seals.

Fig. 5. Removing brake pad wear sensor.

0012156

7. Inspect brake caliper for signs of leakage. Check that the caliper piston slides smoothly into caliper. Replace caliper if any faults are found. CAUTIONWith the pads removed, residual hydreulic pressure may cause the caliper piston to slide out. Use a wooden block to hold the piston in place .

8. fnsert brake pad wear sensor into cutout in new pad where applicable. NOTElf the brake lining indicator light illuminated prior to brake pad replacement, the wear sensor should be replaced.

9 . Slowly press piston back into caliper. Use cace not to damage piston dust sea¡ . See Fig. 6. NOTE" Open caliper bleeder screw when pressing piston back into caliper. Catch expelled fluid in appropriate container. This procedure is highly recommended in the case of cars with ABS.

10 . Thoroughly clean inner and outer surfaces of brake rotor. Inspect rotor for cracks, signs of overheating and scoring. 11 . Measure thickness of rotor. See Table b. If rotor does not pass minimum thickness requirements, or is damaged, replace as described later. 12 . Thoroughly clean all contact points on caliper and brake pad carrier. Clean guide bolts and make sure they slide freely 13 . Lightly coat pad contact points with brake anti-squeal paste. Place outer brake pad onto caliper. Apply a small amount of grease to the top and bottom contact points where the caliper contacts the pad carrier. 14. Place inner brake pad (with locating spring) onto brake caliper piston . Route pad wear sensor wiring through caliper opening and bleeder dust cap. 15 . The remainder of installation is reverse of removal.

" Do not lubricate guide boits. " Once brake assembly is installed depress brake pedal severa¡ times before driving vehicle.

Tightening Torques " Brake caliper to brake pad carrier (guide bolt) . . . . . . . . . . . . . . . 30 Nm (22 ft-Ib) " Road wheel to hub . . . . . . . . 100±10 Nm (74±7 ft-Ib)

" Open the bleeder screw only when applying force to the piston. Do not allow air to be drawn in through the bleeder screw. " Pressing the caliper piston in may cause the brake fluid reservoir to overflow. To prevent this, use a clean syringe to first remove some fluid from the reservoir.

BRAKE PADS, CALIPERS, AND ROTORS

340-6

BRAKES

Caliper guide bolts ,

Bleeder valve and dust cap

Cover

Caliper p Oringiston

bolt~ caps Shoe retaining píns

Guide bolt covers Brake caliper

Brake ad _ i ~wear sénsor (right wheel V . .,,, ! Circli

Brake pad carne

Parking brake cable

Rotor with integrated parking brake drum

6573

Fig. 7. Rear brake caliper assembly.

Brake caliper, removing and installing 1 . Raise car and remove wheel. WARNING Make sure the car is firmly supported on jack stands designed for the purpose.

2. Loosen brake hose fitting at caliper. Do not remove. 3. Remove caliper mounting bolts from steering arm (Font caliper) or from trailing arm (rear caliper) . See Fig. 8. 4. Press piston back into caliper and slide caliper off brake rotor. Spin caliper off brake hose . 5. Inspect brake caliper for signs of leakage. Check that caliper piston slides smoothly into caliper. Replace caliper if any faults are found. 6. Installation is reverse of removal. Bleed entire brake system before driving car. See Bleeding Brakes . Tightening Torques " Front brake caliper to steering arm . . 110 Nm (81 ft-Ib) " Rear brake caliper to trailing arm . . . . 67 Nm (50 ft-Ib) " Brake fluid hose to caliper . . . . 17-19 Nm (13-14 ft-Ib) " Road wheel to hub . . . . . . . . 100±10 Nm (74±7 ft-Ib) BRAKE PADS, CALIPERS, AND ROTÓRS

0011256

Fig. 8. Front brake pad carrier mounting bolts (arrows) . Rear caliper mounting bolts are similar.

BRAKES Brake rotor, removing and installing Brake rotors should always be replaced in pairs . NOTEM3 models use directional brake rotors and must be installed on the proper side. Part numbes are cast finto the rotors . A part that ends in an odd number is a left rotor. One that ends in an even number is a right rotor.

1 . Remove caliper as described-above and hang from chassis using stiff wire . NOTEDo not loosen caliper brake hose .

2. Remove mounting screw holding rotor to wheel hub. See Fig. 9.

340-7

5. Once brake assembly is instalind, depress brake pedal several times to adjust caliper and pads . " Pedal should feel firm and be at proper height . " Check fluid leve¡ . Top up if necessary.

NOTEWhen installing new rear brake rotors, the parking brake should be adjusted. See Parking Brake.

Tightening Torques " Brake rotor to wheel hub . . . . . . . . . . 16 Nm (12 ft-Ib) " Front brake caliper to steering arm . . . 110 Nm (81 ft-Ib) " Rear brake caliper to traíling arm . . . . 67 Nm (50 ft-Ib) " Road wheel to hub . . . . . . 100 ± 10 Nm (74 t 7 ft-Ib) , Table b. Brake Rotor Reconditioning Specificati*M` Vented rotor wear limit (min . thickness) Solid rotor wear limit (min. thickness) M3 models wear limit (min . thickness) Axial runout (max .) rotor removed rotor installed

Front

Rear

20 .4 mm (0.803 in .) 8.4 mm (0 .331 in .) 26 .4mm (0 .977 in .)

18 .4 mm (0 .723 in .)

0 .05 mm (0 .002 in .) 0 .20 mm (0 .008 in .)

CAUTIONM3 brake rotors must not be machined.

MASTER CYLINDER The brake master cylinder is mounted to the front of the vacuum booster on the driver side bulkhead .

Fig. 9. Brake rotor mounting screw (arrow). 3. Inspect rotor for excessive grooving, cracks, and warping . Check rotor thickness. See Table b. NOTEOn original equipment rotors, the mínimum allowable thickness is stamped on the rotor hub. Measure the rotor braking surface with a micrometer at eight to ten different points and use the smallest measurement recorded .

4. Installation is reverse of removal.

" Clean rotor with brake cleaner before installing . " If brake fluid hose veas removed or loosened, brake system must be bled as described above under Bleeding Brakes .

Master cylinder, removing and installing 1 . Using a clean syringe, empty brake fluid reservoir. WARNING Brake fluid is highly corrosive and dangerous to the environment . Dispose of it properly.

2 . Disconnect brake fluid leve¡ sender connector from fluid reservoi r cap. 3. Disconnect brake fluid lines from master cylinder. See Fig . 10 . Disconnect hydraulic clutch system supply line . 4. Unscrew mounting nuts and remove master cylinder from brake booster. 5. Make sure all nuts, fluid couplings, thread bores, and mating surfaces are clean. MASTER CYLINDER

340-8

BRAKES BRAKE BOOSTER The brake booster is mounted to the bulkhead on the driver side of the engine compartment, directly behind the brake master cylinder . See Fig . 11 .

Fig . 10 . Brake fluid lines at master cylinder (arrows) .

0012164

6 . If fluid reservoir was removed, install it carefully using new sealing grommets . 7 . Mount master cylinder to brake booster using a new 0ring and new self-locking nuts . CAUTIONUse cave not to over-torque the master cylinder mounting nuts. This could damage the brake booster and prevent proper vacuum build-up. 8 . Connect all brake fluid lines . Connect hydraulic clutch hose to brake fluid reservoir. 9 . Reconnect fluid leve¡ sender, and bleed entire brake system as described earlier .

Tightening Torque

" Brake master cylinder to brake booster . . . . . . . . . . . . . . . . . . . 26 Nm (18 ft-Ib) " Brake fluid hose to caliper . . . . 17-19 Nm (13-14 ft-Ib)

0015225

Fig. 11 . Brake booster (arrow) . A is vacuum hose from intake manifold . B is one-way valve . Intake manifold vacuum acts on a large diaphragm in the brake booster to reduce brake pedal effort . Brake booster, removing and installing 1 . Disconnect negative (-) cable from battery. CAUTIONPrior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡. 2 . Using a clean syringe, empty brake (luid reservoir. WARNINGBrake fluid is highly corroslve and dangerous to the environment. Dispose of it properly. 3 . Remove brake fluid level sender connector from reservoir cap . 4 . Disconnect brake fluid lines from master cylinder. Plug openings . 5. Disconnect engine vacuum hose from brake booster.

BRAKE BOOSTER

BRAKES

340- 9

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

A . Right front B. Left front C. Rear

11-ri J.

0013244

F Front from master cylinder R . Rear from master cylinder

Fig. 12 . Brake fluid lines at 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 unless this equipment is available. For safety reasons, the brake system on cars with ABS must not be bled using the procedures described in this 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) from beneath steering column to access pedal assembly. See 513 Interior Trim . 9. Remove clip and clevis pin from brake booster pushrod and disconnect it from brake pedal . Remove brake booster mounting nuts. See Fig. 13 . 10 . Working in engine compartment, remove brake booster together with master cylinder. 11 . If booster or master cylinder O-ring is being replaced, disconnect master cylinder from brake booster.

0011261

Fig. 13 . Brake pedal clevis pin 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 . CAUTIONDo 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 " Brake master cylinder to brake booster . . . . . . . . . . . . . . . . . . . 26 Nm (18 ft-Ib) " Brake booster to bulkhead . . . . . . . . . 22 Nm (16 ft-Ib) " Brake fluid line to master cylinder or ABS hydraulic unit . . . . . . . . . . 17-19 Nm (13-14 ft-lb)

NOTEWhen replacing the brake booster one-way valve or vacuum hose, install the valve so that the molded arrow is pointing toward the intake manifold. Use new hose clamps .

12 . Make sure al¡ nuts, fluid couplings, thread bores and mating surfaces are clean.

BRAKE BOOSTER

340- 1 0

BRAKES

PARKING BRAKE The parking brake is a brake drum system integrated into the rear brake rotors . See Fig. 14 . Adjustment of the shoes may be necessary compensate for wear . The parking brake should also be adjusted any time the cable, the rear brake rotor, or the parking brake shoes are replaced . Shoe retainer and spring Shoe adjuster

-í :: <~

Rotor with integrated parking brake drum I

Upper return spring

Fig. 15 . Parking brake cable adjusting nuts (arrows) . Parking brake Parking brake shoe actuator

Lower retum spring

0011263

Rotor mounting screw

0011265

Fig. 14. Parking brake shoe assembly.

Parking brake, adjusting The parking brake can be adjusted with the wheels installed, although the rear wheels will have to be raised off the ground .

1 fl

i\ a

1 . Lift parking brake lever boot out of console. While holding cables stationary, loosen parking brake cable nuts until cables are completely slack. See Fig. 15 . 2. Raise rear of car. WARNING Make sure the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.

3. Remove one lug bolt from each rear wheel . Turn road wheel until lug bolt hole lines úp with parking brake adjuster (approximately 65° to rear of wheel centerline) . See Fig. 16 . 4. Using a screwdriver, turn adjuster to expand brake shoes until road wheel can no longer turn, then back adjuster off. Repeat procedure on other rear wheel.

0012727

Fig. 16 . Access parking brakeshoe adjuster approxímately 65° to rear of vertical . Use flat-bladed screwdriver to turn adjuster. On left wheel, turn adjuster in direction 1 to expand shoes. On ríght wheel, turn adjuster in direction 2 to expand shoes. Parking Brake Adjusting (initial) " Back off adjuster through wheel lug bolt hole ex . M3 models . . . . . . . . . . . . . . . . . . . . . . 18 notches M3 models . . . . . . . . . . . . . . . . . . . . . . . . . . 8 notches 5. Working inside car, set parking brake several times to seat cable. Then pull parking brake lever up four notches . Tighten cable adjusting nuts until it is just possible to turn rear wheels with slight resistance . 6. Release lever and make sure rear wheels turn freely.

PARKING BRAKE

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BRAKES 7. Turn on ignition . Check that light comes on as soon as lever is pulled up . 8. Install parking brake lever boot . Install road wheel lug bolts.

340- 1 1

4. Remove parkíng brake shoes as described above. 5. Disconnect cable from parking brake actuator and then remove parking brake cable from cable holder on trailing arm. See Fig. 17.

Tightening Torque " Road wheel to hub . . . . . . . . . 100±10 Nm (74±7 ft-Ib)

Parking brake shoes, removing and installing 1 . Raise rear of car and remove road wheels. WARNING Make sure the car is firmly supported on jack stands designed for the purpose . Place the jack stands beneath a structural chassis point . Do not place jack stands under suspension parts.

2. Without disconnecting brake fluid hose, remove rear brake calipers from trailing arms . Remove rear brake rotors . See Brake Pads, Calipers and Rotors. CA UTIONDo not let the brake caliper assembly hang from the brake hose. Support caliper from chassis with strong wire.

3. Unhook upper return spring from brake shoes. Remove shoe retainers by pushing them in and rotating 1/4 turn . BMW special tool no . 34 4 000 can be used to remove retainers, if needed . 4. Spread shoes apart and lift them out. NOTEWhen removing the brake shoes the shoe expander pivot pin in the brake actuator may fall out.

5. Inspect shoe expander to make sure it functions properly. Apply a thin coat of grease to sliding parts and pins . 6. Installation is reverse of removal . Be sure to adjust parking brake cables as described earlier.

Parking brake cable, replacing

1 . Raise rear of car and remove road wheels . 2. Remove rear brake caliper and rotor. See Brake Pads, Calipers and Rotors .

0013209

Fig. 17. Parking brake cable insertion point in rear trailing arm (arrow). 6. Slide cable out of housing. NOTE On some models it may be necessary to remove rear muffler to access the brake cabes) .

7. Installation is reverse of removal. Adjust parking brake as described earlier.

ANTILOCK BRAKE SYSTEM (ABS) Two versions of the Antilock Brake System (ABS) are installed on the cars covered by this manual . Early cars use the Teves Mark IV G ABS. Later cars use the Teves Mark 20-I ABS. The main difference between the two systems is that the Mark 20-I system integrates the ABS control module into the hydraulic unit as a single component. ABS is designed to be maintenance free . There are no ad justments that can be made to the system . Repair and troubleshooting of the major ABS components requires special test equipment and knowiedge and should be done by an authorized BMW dealer .

3. Working inside car, lift parking brake lever boot out of console . Remove cable adjusting nut. Refer to Fig. 15 . ANTILOCK BRAKE SYSTEM (ABS)

340- 1 2

BRAKES

ABS is self-tested by the ABS diagnostic unit each time the car is started. Once the test is complete, the ABS dashboard light tucos off. If the light remains lit or comes on at any time during driving, a system fault has occurred and ABS is electronically disabled. The conventional braking system remains fully functioning .

ABS Inspection A visual inspection of the ABS may help to locate system faults . If no visual faults can be found and the ABS light remains on, have the system diagnosed by an authorized BMW dealer . Carefully inspect the entire ABS wiring harness, particularly the pulse sensor harnesses and connectors near each wheel. Look for chafing or damage due to incorrectly routed wires. Carefully remove the wheel speed sensors. Clean the sensor tips . Inspect the toothed wheel on the wheel hub. Check for missing, clogged or corroded teeth, or other damage that could alter the clearance between the sensor tip and the toothed wheel.

Fig. 18. Front ABS pulse sensor mounting bolt (arrow).

NOTEIf a toothed ring is damaged, the entire wheel hub must be reptaced. See 310 Front Suspension or330 Rear

Suspension .

ABS wheel speed sensors, replacing 1 . Raise applicable end of car. WARNING Make sure the car is firmly supported on jack stands designed for the purpose . Place the jack stands beneath a structural chassis point Do not place jack stands under suspension parts.

2. Unscrew wheel speed sensor mounting bolt . Remove sensor from its housing . See Fig. 18 . Remove harness from retaining mounts . 3. Front ABS sensor: Working in front wheel housing, disconnect and remove sensor . See Fig. 19 . 4. Rear ABS sensor : Working in rear wheel housing, disconnect and remove sensor. 5. During installation, apply thin coat of Molykote 0 Longterm 2 or an equivalent grease to pulse sensor and housing.

ANTILOCK BRAKE SYSTEM (ABS)

0012122

Fig. 19 . Front ABS wheel speed electrical connector (arrow) in wheel well. 6. Installation is reverse of removal .

BODY-GENERAL

400-1

400 Body-General GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-1 BODY ASSEMBLY . . . . . . . . . . . . . . . . . . . . .400-2

Exterior and Aerodynamics . . . . . . . . . . . . . . . 400-2 Coupe Models . . . . . . . . . . . . . . . . . . . . . . . . . 400-3 Convertible Models . . . . . . . . . . . . . . . . . . . . . 400-3

GENERAL This section covers system descriptions and general service information for the repair groups found in 4 Body and 5 Body Equipment. When working or servicing cars equipped with SRS airbag(s), the following precautions must be observed to prevent injury .

INTERIOR EQUIPMENT . . . . . . . . . . . . . . . . 400-4 Seats and Seatbelts . . . . . . . . . . . . . . . . . . . . . 400-4 Instruments and Controls . . . . . . . . . . . . . . . . . 400-4 Central Body Electronics . . . . . . . . . . . . . . . . . 400-5 Electronic Immobilization System . . . . . . . . . . 400-5 Heating and Air Conditioning . . . . . . . . . . . . . . 400-6

WARNING " Airbags are inflated by an explosive device . Handled improperly or without adequate safeguards, airbag units can be very dangerous. Special precautions must be observed prior to any work at or near the driver's side airbag, the passenger's side airbag (where applicable), or the side-impact aírbags (where applicable) . See 721 Airbag Sys-

tem (SRS).

" Always disconnect the battery and cover the negative (-) battery terminal with an insulator before starting diagnostic, troubleshooting or service work on cars fitted with SRS, and before doíng any welding on the car.

0013098

F19.1 . The BMW E36 coupe .

GENERAL

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400-2

BODY-GENERAL

4-door Sedan

saas3.7"" 351

55 ass.e iss"" - 66 .9 -

29 .4

x`-193

37.3 267

706 .31108.7"

o I

38 .5

55 9/563'/566" -J

174 .5

Coupe

O 55

294

196 .3/106 .7'"

35_5

174.5

1..

.9,566 ".

Convertible

106 .3/196.7"" '3281 model "M3 model

i .

358

-17450013099

Fig. 2. E36 body dimensíons .

BODY ASSEMBLY The BMW 3 Series chassis is a unibody design constructed of high strength steel. Attaching parts, such as the front fenders, rear quarter panels, doors, trunk lid and hood are also constructed of steel . The body styles of E36 cars covered by this manual are the 4-door sedan, 2-door coupe and convertible . Body dimensions vary slightly between models . See Fig. 2.

Exterior and Aerodynamics The E36 can be immediately recognized as a typical BMW. With its traditional styling features, such as the BMW kidney grille, circular headlights behind a glass cover (for reasons of streamliníng), and the "kick" in the rearmost roof pillar (C-pillar) .

BODYASSEMBLY

Windows bonded flush to the body and the guided flow of cooling air into the engine compartment provide a good coefficient of drag (CD) . The E36 cars have a CD of approximately 0.30 for the sedan and coupe models, and 0.35 for the convertible models : The exterior panels are corrosion-resistant zinc coated steel . The front fenders are bolted on and easily replaceabie . See 410 Fenders, Engine Hood . The front and rear bumpers use an aluminum framework with an overlaid high-impact, deformable plastic cover. This bumper system keeps damage to a minimum in head-on collisions of up to 10 m.p .h . (15 km/h). See 510 Exterior Trim, Bumpers.

BODY-GENERAL Coupe Models The E36 coupe is similar to the 4-door sedan, but has a more stretched and sleeker appearance . Thus, with the same wheelbase and identical length, it looks different but still familiar. The 2-door variant differs from the 4-door sedan by a 3.12 inch (8 cm) longer front end, a flatter hood line with air slits, and a roof almost 1 .2 inches (3 cm) shorter . Additional differences include wider doors with frameless Windows, glasscovered door-posts (B-pillars) and a shorter and lower luggage compartment lid.

Convertible Models The E36 convertible is an all-season vehicle with a high leve¡ of functionality, excellent interior comfort, and acoustic refinement . Interior materials and colors, the soft top and the light-alloy wheels have been carefully matched. Various versions of manual and automatic soft tops have been used, with the fully automatic convertible roof being installed beginning in the 1997 model year. A hard-top in body color with heated rear window is available as an option forthe cold season .

400-3

The convertible body structure includes many passive safety refinements over its fixed-top counterparts . Some of the enhancements include: " More rígíd underbody. " Transverse seat members. " Reinforced windshield frame with bonded windshield, and tubular door reinforcements . " Rollover protection system, which is tripped into position in a fraction of second . This is available as optional equipment (standard on the 1998 328iC) and may be fitted to earlier convertible models . With this feature, two bars fully independent of each other come up behind each rear-seat backrest when the vehicle is in danger of turning over. A convertible body normally flexes and vibrates, transferring oscillations to the luggage compartment . In the E36 convertible, BMW utilizes a special battery in the luggage compartment, in conjunction with a unique battery tray, as a vibration dampening system to counteract this oscillation. CAUTION -

The E36 convertible requires a special battery which is designed for constant vibration .

Information for the convertible top and its related mechanisms can be found 541 Convertible Top.

BODYASSEMBLY

400-4

BODY-GENERAL

INTERIOR EQUIPMENT E36 interiors have a unique character, with a combínation of sporty features and innovative design . Al¡ body versions were made in a wide choice of interior and exterior colors . New colors with matching leather and/or fabric upholstery were introduced for each model year, including light-alloy wheels in new designs. Driving comfort is enhanced by power steering, tilt steering wheel (optional), height-adjustable front seats, and electrically adjustable and heated rear-view mirrors. Inside the car there are reading lights at four seating positions.

Seats and Seat Belts Anatom¡cal ly-correct seats are constructed from polyurethane foam containing areas or "zones" of different firmness . The seat bases have steel springs for added support and strength . The power seats are provided with conveniently located switches along the outside edge of the seat . Heated seats are an option in all models . See 520 Seats for more details. The M3 sport seat is shown in Fig. 3.

The early E36 cars are equipped with a single (driver side) airbag in the steering wheel. Starting with the 1994 models, a dual airbag Supplemental Restraint System has been standard equipment. Side-impact airbags in the front doors are optional in 1997 4-door cars and standard equipment in all 1998 models . Through 1996, E36 seatbelts were equipped with BMW's original-design spring tensioners . In 1997, the seat base design was modified to accommodate a pyrotechnic (explosive charge) seatbelt tensioner. Both types of tensioners are designed to automatically tension the belts by about 2 inches (55 mm) in the event of a collision . NOTEThe seat base used on cars with pyrotechnic seatbelt tensioners is not interchangeable with the earlier seat base.

Instruments and Controls Everything in the interior passenger compartment essential to the driver is logically grouped and easy to reach. Al¡ instruments and controls have been arranged ergonomically and are fully integrated into the overall design of the vehicle. The padded dashboard houses the instrument cluster and the ventilation and heating system . The instrument cluster uses large easy-to-read analog instruments and is removable as a unit without removing the dashboard. The Service Interval Indicator (SII) will remind the driver when the car requires service . See 620 Instruments. The Multi-Information Display (MID) unit in the center of the dashboard comes in a variety of four configurations, the most advanced being the On-Board Computer (OBC). See Fig . 4.

0013195

Fig. 3. M3 sport seat .

INTERIOR EQUIPMENT

Al¡ versions of the MID have a clock and calendar . In addition, different versions are equipped with a "check control," display for fuel-economy information and system warnings . Consult the owner's manual for fui¡ operating instructions .

BODY-GENERAL

400-5

Two versions of central body electronics are used depending on model year .

Ambient temperaturelclock

1992 and 1993 models are equipped with a central locking module (ZVM) which incorporates control of the following systems : " Interior lighting " Central locking with double lock feature " Output relays for power windows and sunroof " Electronic power protection

MÍMA a.Mi}rm -Mil "IMua~naa~u~itacar"za .~

E36 cars since the 1994 model year are equipped with ZKE IV. This is an electronic comfort and convenience system that includes the following additional features : " One touch up/down power window operation " Power window and sunroof closure from driver or passenger door lock " Vehicle locking or unlocking from the trunk lock . Other features of the system are discussed in 515 Central Locking and Anti-Theft .

Electronic Immobilization System Beginning in model year 1994, all E36 vehicles incorporate a driveaway protection system regardless of whether the vehicle is equipped with a BMW Alarm System or an On-Board computer. Two types of factory systems were installed, depending on vehicle production date . 0013028

Fig. 4. Different versions of Multi-information Display (MID) installed in E36 cars.

Central Body Electronics The E36 cars are equipped with a sophisticated centralized body electric/electronics plan . The system is self-diagnostic and incorporates many functions into a single control module . The consolidation of several systems into a single control module minimizes power requirements and the incorporation of the diagnostic link results in more efficient and accurate troubleshooting . Self-diagnostic codes are accessible electronically through the data-link connector in the engine compartment. See 610 Electrical Component Locations.

On the early system (model year 1994 up to January 1995), the ignition and fuel injection functions are disabled whenever the vehicle is locked in the double lock mode . This is referred lo as EWS or EWS I. Beginning in January 1995, the driveaway protection system was upgraded to a more sophisticated system, called EWS II . This system uses a wireless communication link between a transponder chip in the ignition key and the ring antenna surrounding the ignition switch . The EWS II control module blocks the starting of the vehicle unless the correct coded ignition key is used . For further information about drive away protection systems, see 515 Central Locking and Anti-Theft .

INTERIOR EQUIPMENT

400-6

BODY-GENERAL

Heating and Air Conditioning The electronically controlled heating and air conditioning system uses an extra large, infinitely variable radial blower motor for good distribution of air. Fresh air enters through the grille below the engine hood and finto the passenger compartment via the dashboard and footwell vents. See Fig . 5. Repair information for the heating and air conditioning system is covered in 640 Heating and Air Conditioning .

Fig. 5. Heating and air conditioning ventilation plan .

INTERIOR EQUIPMENT

FENDERS, ENGINE HOOD

410-1

410 Fenders, Engine Hood GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410-1 FRONT FENDERS . . . . . . . . . . . . . . . . . . . . .410-1

Front Pender, removing and installing . . . . . . . 410-1

ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . .410-3

Hood, raising to service position . . . . . . . . . . . 410-3 410-3 Hood, removin and installin Hood, aligning . . . . . . . . . . . . . . . . . . . . . . . . . 410-4 Hood release cable and latches, adjusting . . . 410-4

GENERAL This repair group covers replacement of the front fenders and removal and installation of the engine hood. NOTEThe body is painted at the factory after assembly. Realignment of body panels may expose unpainted metal. Paint all exposed metal once the work fs complete.

FRONT FENDERS Front fender, removing and installing 1 . Raise hood . Raise and safely support front of vehicle. WARNING " When raising the car using a floor jack or a hydraulic lift, carefully position the jack pad to prevent damaging the car body. A suitable liner (wood, rubber, etc .) should be placed between the jack and the car to prevent body damage. " Watch the jack closely. Make sure it stays stable and does not shift or tilt. As the car is raised, the car may roll slightly and the jack may shift.

2. Remove front wheel. Remove inner plastic liner from wheel well . 3. Remove front bumper. See 510 Exterior Trim, Bumpers. 4. Working at front corner of fender, remove front grille panel bolts (2 bolts at left and right) . See Fig. 1 .

001 .145

Fig. 1. Front grille panel to frontfender retaining bolts (arrows) . Front bumper shown removed. 5. Remove front turn signalliens assembly from applicable front corner. Carefully pry out side directional from fender (later cars only). See 630 Exterior Lighting . 6. Remove fender attaching bolts at front underside of fender. See Fig. 2. 7. Remove bolts along top edge of fender : See Fig. 3. 8. Open front door and remove fender mounting bolts in door jamb . See Fig. 4. 9. Carefully remove fender from body.

FRONTFENDERS

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410-2

FENDERS, ENGINE HOOD

Fig . 2. Fender attaching bolts, lower front (arrows).

0013104

Fig . 4 .

0013106

Front fender attaching bolts as viewed through doorjamb (arrows) .

10 . Installation is reverse of removal, noting the following : " Before installing new fender, clean old sealant and protective coating from mounting surfaces. " Position new fender and loosely install all mounting bous . Align fender with door pillar and front panel, then tighten bolts . " Repair any paint damage and paint any exposed metal . " Reseal and apply protective coating to mounting surfaces .

Clearance Specification " Fender to front hood or to door . . . . 5 .5 mm (0 .216 ín)

Fig . 3. Loosen bolt A at top of fender. Remove bolts B .

0013105

FRONTFENDERS

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FENDERS, ENGINE HOOD

410- 3

ENGINE HOOD Hood, raising to service position CA UTION-

Do not switch on the windshield wipers wlth the engine hood raised. As a precaution, remove the wiper motor fuse. See 610 Electrical Compo-

nent Locations.

1 . 4-door models : Open hood fully. Remove bolt from hood hinge behind hood supports (left and right) . Raise hood to service position . See Fig. 5.

0013147

Fig. 6. Torx screw at base of hood hinge (arrow).

Hood, removing and installing 1 . Raise hood . Where applicable, partially remove hood acoustic insulation to access rear of hood . See Fig. 7.

Fig. 5. Hood support bracket bolt to be removed (A) on 4-door cars . Remove bolts at left and right hinges . Swing bracket in direction of arrow to raise hood into service position . 2. 2-door models : Open hood fully. " Remove ground cable at right hood hinge. " While an assistant supports hood, detach both hood supports from hood . " Remove detent screws at back of hood hinges . See Fig. 6. " Lift hood while pulling hinge forward. Support hood at higher position . 3. When service work is complete, return hood to lower position and instaf screws or bolts.

0013148

Fig. 7. Hood insulation retainer being pried out

2. Disconnect washer fluid hoses from washer nozzles. Where applicable, disconnect electrical harness connectors from heated nozzles. 3. Detach gas-charged hood supports from hood . CAUTION -

The hood is heavy. Before removing the hood supports or hood retaining bolts, be sure to have an assistant help support the hood.

ENGINE HOOD

410-4

FENDERS, ENGINE HOOD

4. With aid of assistant, remove hood hinge bolts from left and Rght sides of hood . Lift hood off carefully See Fig . 8.

6013150 Fig. 9. Hood panel gaps should be even (approx. 5.5 mm) at all points (arrows) .

Fig. 8. Hood hinge bolts (arrows) . Right side shown .

0013149

5. Installation is reverse of removal.

" Repair any paint damage and paint any exposed metal. " Check hood alignment as described next . NOTEThe hood was fitted and attached to an unfinished body at the factory. Unfinished surfaces exposed by this procedure must be touched up wfth pafnt.

Hood, aligning When installing the hood, align the hinges as close to the original painted surface as possible . Movement of the hood on its'attaching hardware may require touch-up paint. The hood should be aligned so that gaps on all sides are as even as possible . See Fig. 9. Clearance Specification " Hood edges to adjoining body panel (gap) . . . . . . . . . . . . . . . . . . . .5 .5 mm (0 .216 in)

Hood release cable and latches, adjusting Before adjusting hood latches, be sure the hood is aligned evenly to fenders and front panel. The hood latch and cable assembly is shown in Fig. 10 . 1 . To adjust hood cables : " Remove left and right radiator grilles. See 510 Exterior Trim, Bumpers. " Remove electric auxíliary cooling fan . See 170 Radiator and Cooling System . " Adjust cable section between two hood latches so there is no play (cables must not be under tension either) . 2. Loosen hood latches at hood on left and right sides. Loosen bolts only enough to allow movement of latch. See Fig. 11 . 3. Lower (but do not fully latch) hood severa¡ times so latches on hood center themselves in lower locks. CA UTIONDo not let hood fock with latch bolts loose.

4. Tighten hood latch bolts when alignment is correct. 5. Remove one screw from each side, clean and coat with LoctiteO270 or equivalent, and reinstall.

ENGINE HOOD

FENDERS, ENGINE HOOD

Center hood cable _ I

410-5

00--&--- Hood latch upperleft

Hood lock lower left

0013160

Fig . 10 . Hood locking components . Cable adjusting section shown at inset .

001aio

Fig . 11 . Hood latch mounting bolts (arrows) . Left latch shown .

Fig . 12. To lengthen spring pin, loosen locknut with wrench inserted through spring, then turn pin (arrow) counterclockwise .

6 . Test hood for correct closure and opening . If hood does not spring open, lengthen spring pins at latches . See Fig . 12 .

ENGINE HOOD

DOORS

411-1

411 Doors GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411-1 DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411-1

Front or rear door, removing and installing . . . 411-1 Door check, replacing . . . . . . . . . . . . . . . . . . . 411-3 Door Adjustment . . . . . . . . . . . . . . . . . . . . . . . 411-3

DOOR PANELS . . . . . . . . . . . . . . . . . . . . . . . . 411-4

Front door trim panel, removing and installing .411-4 Rear door trim panel, removing and installing .411-5 Rear side trim panel, removing and installing (coupe model) . . . . . . . . . . . . . . . . . . . . . . . .411-6 Rear side trim panel, removing and installing (convertible models) . . . . . . . . . . . . . . . . . . . 411-6

GENERAL This repair group covers front and rear door repair information, including removal and installation of the interior door panels. WARNING -

Late M3 moddis have aluminum doors. Use extra care in handling aluminum parts in order to avoid damage from gouging or corrosión. NOTE" For information on the power door windows and door glass replacement, sea 512 Door Windows. " Forinformation on the power door locking system, see 515 Central Locking and Anti-Theft.

DOORS WARNING -

Some 1997 and all 1998 cars are fitted with side-impact airbags in the front doors. When servicing doors on cars with front side-impact airbags, always disconnect the negative (-) battery terminal. See 721 Airbag System (SRS) for cautions and procedures relating to the airbag system.

Fig. 1 . Door harness connector being removed from door pillar. Remove mounting screws at A, then separate connector by pulling up on harness lock (top arrow) . 3. With door fully open, remove pin bolts from top and bottom door hinges . See Fig. 2.

Front or rear door, removing and installing

1 . If working on front door with side-impact airbag, disconnect negative (-) battery cable. CAUTION -

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page vüi.

2. Unbolt main harness connector at door pillar and separate connector. See Fig. 1 .

0011650

Fig. 2 . Door hinge pin bolt (arrow). Top hinge shown. Also remove pin bolt from lower hinge. DOORS

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411-2

DOORS

4. Remove retainer clip (early models only) from door check pin on body pillar. Drive out door check pin. See Fig. 3.

Door Adjustment " Door gap to fender/rear door . . . . . . . . . approx . 5 mm (0.189 in) " Permíssible deviation from parallel . .0 .5 mm (0.020 in)

Door check, replacing WARNING -

Some 1997 and all 1998 cars are fitted with side-impact airbags in the front doors. When servicing doors on cars with front side-impact airbags, always disconnect the negative (-) battery terminal. See 721 Al rbag System (SRS) for cautions and procedures relating to the airbag system.

1 . Close door window completely. 2. If working on front door with side-impact airbag, disconnect negative (-) battery cable. , 0011651

Fig. 3. Door check pin being removed . Note retainer clip (A) used on early models . 5. Remove door by lifting up off lower hinge halves . CAUTION-

Be careful not to damage door or other painted body surfaces . Make sure no load is placed on wiring harness .

6. Installation is reverse of removal. Keep in mind the following :

" Align door so that panel gaps are equal on either side, as described later. If necessary, adjust door hinges as described later. " Adjust door striker so that trailing edge of front door is slightly higher (1 mm) than leading edge of rear door. See 515 Central Locking and Anti-Theft . " Repair any paint damage and paínt any exposed metal . CAUTION- .

" In 2-door models, removing and installing the door may upset the adjustment and alignment of the window. Window adjustment, as described in 512 Door Windows, must be carried out ater installation to prevent damaging the glass . " If battery power is lost or the battery has been disconnected, the windows must be re-initialized. Both one touch upldown and pinch-protection will be inactive until windows are re-initialized. See

512 Door Windows.

DOOR CHECK, REPLACING

CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions gíven at the front of this manual on page viii.

3. Remove interior door panel and vapor barrier as described later. 4. Where applicable, remove side-impact airbag from door . See 721 Airbag System (SRS). NOTE-

In some models covered in this manual, ít is not essential to remove the side-ímpact airbag to access internal door components. However, the procedure is recommended for safety reasons.

5. Remove retainer clip (early models only) from door check pin on body pillar. Drive out door check pin. Refer to Fig. 3. 6. Remove bolts and rubber cover from door check lockplate on door. 7. Remove door check from inside door. 8. Installation is reverse of removal .

" Lubricate door check before installing . " Use new mounting bolts when reinstalling the side-impact airbag to the door (where applicable) . " If battery was disconnected, re-initialize window regulator motors as described in 512 Door Windows.

DOORS Door Hinge Adjustment If the installed door is uneven or out of parallel, shims can be used to correct its position . The shims are placed behind the hinge plate and are available in two different thicknesses (0 .5 mm and 1 .0 mm). See Fig. 4.

411-3

2. Carefully pry out mirror adjustment switch and disconnect harness connector from switch . Fig. 5.

Tightening Torque " Door hinge to door . . . . . . . . . . . . . . 21 Nm (15.5 ft-I b) " Door striker to door . . . . . . . . . . . . . . 25 Nm (18 ft-Ib)

Fig. 5. Pry outside mirror switch from door armrest .

0013168

3. Unscrew door locking knob . 0 l

0013102

4. Pry off trim cover for insíde door handle . Pry off concealing plugs from armrest. Remove door panel retaining screws . See Fig. 6.

Fig. 4. Door hinge and door check components . Front and rear doors are similar.

DOOR PANELS WARNING Some 1997 and all 1998 cars are fitted with side-impact airbags in the front doors. When servicing doors on cars with front side-impact airbags, always disconnect the negative () battery terminal. See 721 Airbag System (SRS) for cautions and procedures relating to the airbag system.

Front door trim panel, removing and installing 1 . On cars with side-impact airbags, disconnect negative (-) battery cable. CAUTION-

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

Fig. 6. Pry off plugs (arrows) and remove screws .

UU13169

5. Unclip door panel from door perimeter. See Fig. 7.

DOOR PANELS

411-4

DOORS Rear door trim panel, removing and installing

1 . Open door and pry out power window switch . Disconnect harness connector.

2. Remove ash tray. 3. Pry off trim cover from inside door handle . 4. Pry off concealing plugs from armrest. Remove door panel retaining screws . See Fig. 9.

Fig. 7. Door panel being unclipped from door. Pull panel retaining clips off one at a time. 6. Disconnect radio speaker harness connector.

7. Installation is reverse of removal, noting the following:

" Replace any damaged plastic parts or clips. " Renew vapor barrier if it is damaged. " Use new mounting bolts when reinstalling the side-impact airbag to the door (where applicable) . " When installing door panel, align metal retainers on window sill with openings on top of door panel. See Fig. 8. " Check door-lock mechanism and window for ease of movement . " If battery was disconnected, re-initialize window regulator motors as described in 512 Door Windows.

Fig. 9. Pry off plugs (arrows) and remove screws . 5. Unscrew door locking knob . 6. Unclip panel from door perimeter, starting at the top of the door. 7. Installation is reverse of removal .

" Replace any damaged plastic parts or clips. " Renew vapor barrier if it is damaged. " Align metal retainers on window sill with openings in trim panel. Refer to Fig. 8. " Check door-lock mechanism and window for ease of movement .

Rear side trim panel, removing and installing (coupe models) 1 . Remove rear seat cushion. Remove rear backrest side section. See 520 Seats. 2 . Pull off edge trim at bottom of rear side window. See Fig. 10 . 373

Fig. 8. Metal retainers at base of window should be in position to mate with openings in door trim panel.

3. Gently unclip trim panel and remove . 4. Installation is reverse of removal .

" Replace any damaged plastic parts or clips.

DOOR PANELS

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Fig. 10 . Panel edge trim piece trim being removed.

Rear side trim panel, removing and installing (convertible models) To remove the rear side panel in convertible models it is necessary to : " Remove rear seat cushion and rear backrest side section . " Lower side window ; open convertible roof . " Left side : Remove convertible top lid release lever trim . " Remove power window switch and disconnect harness connector. " Remove door panel inset by pulling forward. " Remove corner protector rubber trim . " Pull off side panel after removing screw fastener(s) . Disengage from front shoulder belt.

TRUNK LID

412-1

412 Trunk Lid GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-1 TRUNK LID . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-1

Trunk lid, aligning . . . . . . . . . . . . . . . . . . . . . . . 412-2 Trunk lid support strut, removing and installing . . . . . . . . . . . . . . . . . 412-2

Trunk lid, removinb and installing . . . . . . . . . . 412-1

GENERAL

3. Disconnect wiring from electrical components and remove complete wiring harness from trunk lid.

This repair group covers trunk lid removal and installation . Also inciuded here are replacement procedures for the gascharged support struts that hold the trunk lid in the up position . NOTE The body ís painted at the factory after assembly. Realignment of body panels may expose unpainted metal. Paint all exposed metal once the work is complete .

4. While supporting trunk lid, loosen top hinge bolts and remove lower bolts from left and right sides. Remove trunk lid with`aid of helper. See Fig. 2. NOTEBefore loosening hinge bolts, mark hinge and hinge bolt locations for reínstallation .

TRUNK LID Trunk lid, removing and installing 1 . Raise trunk lid. Open tool kit and remove screws attaching tool kit lo trunk lid. 2. Remove insulating liner from underside of trunk lid . See Fig. 1 .

0013163

Fig. 2. Trunk lid hinge bolts (arrows) . Loosen upper bolt and remove lower bolt .

Fig. 1 . Trunk lid liner retaining screws and clips (arrows) .

0013162

5. Installation is reverse of removal. If necessary, align trunk lid to body as described next .

TRUNK LID

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

412-2

TRUNK LID

Trunk lid, aligning

8. Open trunk lid and screw out rubber stops so that closed trunk lid is flush with top of rear fenders.

1 . Raise trunk lid. 2. Loosen boits at trunk lid lock until it can just be moved. See Fig. 3.

9. Reinstall gas pressure strut. Seam Clearance Specification " Trunk lid to rear fender or bumper . . . . . . . . . . 4.3 - 5.3 mm (0 .169 - 0.209 in) " Max. deviation from parallel . . . . . . .0.5 mm (0 .019 in)

Trunk lid support strut, removing and installing WARNING Make sure to support trunk lid before removing strut

1 . Open trunk lid . Remove spring clip from support strut and remove strut from body end. See Fig. 4.

Fig. 3. Trunk lid lock mounting boits (arrows) .

0013172

3. Loosen bolis at left and right trunk hinges until lid can just be moved. 4. Working at lower comers of trunk lid, screw in rubber buffers on left and right sides fully. 5. Prop open trunk lid and remove gas pressure strut as described below. WARNING " Make sure to support trunk lid before removing strut. " Trunk lid with gas pressure strut removed will drop without damping.

6. Close trunk lid and align lid to body at rear and front. Open trunk lid and tighten hinge bolis. 7. Adjust lock so that closed trunk lid is approximately 1 mm (0 .04 in .) below top of rear fenders. Tighten lock bolts.

TRUNK LID

Fig. 4 . Support strut spring clip (arrow) at body end. 2. Remove strut from trunk lid. 3. Installation is reverse of removal. Replace any trim retaining clips damaged during removal.

EXTERIOR TRIM, BUMPERS

510-1

510 Exterior Trim, Bumpers GENERAL . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 510-1 OUTSIDE REAR VIEW MIRRORS . . . . . . . . . . 510-1

Outside mirror glass, replacing . . . . . . . . . . . 510-1 Outside mirror housing, removing and installing . . . . . . . . . . . . . . . . 510-1 Outside mirror, removing and installing . . . . . 510-2

BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-3 Front bumper, removing and installing . . . . . . 510-3

Front bumper impact absorber, replacing . . . . 510-4 Rear bumper, removing and installing . . . . . .510-4 Rear bumper impact absorber, replacing . . . . 510-6 Bumper height, adjusting . . . . . . . . . . . . . . . . 510-6

EXTERIOR TRIM . . . . . . . . . . . . . . . . . . . . . . 510-6 BMW embiem, removing and installing . . . . . . 510-7 Body side molding, replacing . . . . . . . . . . . . . 510-7 Radiator grille, removing and installing . . . . . .510-7 Front panel, removing and installing . . . . . . . . 510-7

GENERAL This repair group includes repair information for the outside rear view mirror, front and rear bumpers, and the easily removable exterior trim parts.

OUTSIDE REAR VIEW MIRRORS The remove controlled mirrors come in two styles : heated and unheated . Many of the mirror components are separately available from an authorized BMW dealer, including the glass and outside plastic housing.

Outside mirror glass, replacing CAUTIONMirror should be at or above room temperature before removal. Otherwise, small plastic parts or glass will break.

1 . Insert thin pry tool (wooden or tape-wrapped screwdriver) between bottom mirror edge and mirror housing and carefully pry out mirror glass from housing. See Fig. 1 . 2. Heated mirror: remove heating element harness connectors from back of mirror glass. 3. Install new glass into position by pressing firmly until it snaps into place.

00130 ..

Fig. 1 . Prying mirror glass out of mirror housing. Note screwdriver shaft wrapped with tape .

Outside mirror housing, removing and installing 1 . Remove mirror glass as described above. 2. Remove housing retaining screws and lift off rear housing. See Fig . 2. 3. Tilt mirror housing forward and compress plastic retainers and lift off front housing . See Fig. 3. 4. Installation is reverse of removal. Check mirror function before installing covering parts.

OUTSIDE REAR VIEW MIRRORS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

510-2

Fig. 2 .

Fig . 3 .

EXTERIOR TRIIVI, BUMPERS

Mirror housing retaining screws (arrows) .

Use need1e-nose pliers to release retainers (arrows).

0013039 0013041

Fig . 4 .

Pry plastic trim in direction of arrow 1, then lift off in direction of arrow 2 .

Fig . 5 .

Mirror mounting bolts (arrows) . Two-door body style shown .

0013040

Outside mirror, removing and installing 1 . Remove triangular trim plate by prying and lifting gently from door frame . See Fig . 4 . Unhook harness splice connector from base of trim píate . 2 . Separate harness connector. Support mirror and remove mirror mounting bolts . Lift mirror off door. See Fig . 5 . 3 . Installation is reverse of removal . Check mirror function before installing covering parts .

Tightening Torque " Outside mirror to door (M6) . . . . . . . . . 6 Nm (4 .5 ft-Ib)

OUTSIDE REAR VIEW MIRRORS

0013042

EXTERIOR TRIM, BUMPERS

510-3

BUMPERS Front bumper, removing and installing Refer to Fig. 6. when removing and installing the front bumper . 1 . Raise and properly support vehicle. WARNING Make sure that the car is firmly supported on jack stands designed for the purpose . Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts .

2. Unclip left trim strip by prying gently under plastic trim at front of bumper. Similarly, unclip towing eye cover from right side .

Fig . 7 .

5 . Remove bumper cover retaining screws in front wheel well (left and right sides) . See Fig . 8.

3. Remove four mounting nuts from bumper mounts (two nuts on each mount) . See Fig . 7.

6. Disconnect harness connectors at foglight sockets (if applicable) .

4. Working underneath car, remove screws from left and right side corner trim, then remove trim .

Bumper cover

Front bumper mounting nuts (arrows) . Left trim and tow eye cover on right have been removed .

Side corner trim

Support bracket Impact absorber

Side brackets o

Foglight support

LBumner bracket bolt

License plata bracket Fig . 6 .

0011944

Front bumper assembly. BUMPERS

510-4

EXTERIOR TRIM, BUMPERS

Bumper cover retaining screws (arrows) in left wheel weil .

Fig . 8 .

7 . Disconnect harness connectors at outside temperature sensor at rear of left side of bumper and temperatura switch at rear of right side of bumper (if applicable) .

Fig. 9. Front bumper impact absorber mounting nuts (A) and bumper bracket hardware (B) .

8 . Slide bumper straight off sida brackets .

Rear bumper, removing and installing

9 . Installation is reverse of removal, noting the following:

When removing and installing the rear bumper or its components, referto Fig . 10 .

" Slide side brackets on bumper and body carefully together. " Make sure tabs on trim strip engage slots in bumper correctly.

Tightening Torque " Bumper to bumper bracket (M8 nut) . . . . . . . . . . . . . . . . . 22 Nm (16 ft-Ib)

Front bumper impact absorber, replacing The bumper mounting bracket and impact absorber mounting hardware are accessible with the Font bumper removed, as described above . See Fig. 9 . NOTE Install the bumper bracket bolt with thread locking compound such as Loctite8270 or equivalent.

0013052

1 . Raise and properly support vehicle. WARNING Make sure that the car is firmly supported on jack stands designad for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts. 2 . Working under bumper, remove screws or expansion rivets at corners and middle of lower bumper panel . Pull panel backward, uncoupling it from bumper cover. See Fig . 11 . 3 . Remove bumper cover expansion rivets and screws inside left and right rear wheel wells . 4 . Remove left and right bumper bracket mounting bolts and remove bumper. See Fig . 12 . 5 . Installation is reverse of removal .

Tightening Torques " Bumper bracket to impact absorber (M10 nut) . . . . . . . . . . . . . . . . . . . . : . 55 Nm (41 ft-Ib) " Impact absorber to chassis (M6 nut) . . . 9 Nm (7 ft-Ib)

NOTEInstall the bumper bracket bolt with thread locking compound such as Loctite®270 or equivalent.

BUMPERS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

EXTERIOR TRIM, BUMPERS

510-5

Fig. 10 . Rear bumper assembly.

0013045

Fig . 11 . Expansion rivet at corner of rear bumper lower panel (arrow) . Some models use screws . Pull panel backward to disengage from bumper cover.

0013047

Fig . 12 . Insert tool through rear bumper mount bores to remove mounting bolts (right side shown) .

Tightening Torque " Bumper bracket to impact absorber (M10 bolt) . . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 ft-Ib)

BUMPERS

510-6

EXTERIOR TRIM, BUMPERS

Rear bumper impact absorber, replacing 1 . Remove bumper as described above. 2. Remove luggage compartment floor covering . 3. Right side : Remove battery and battery tray. 4. Remove fasteners from left or right luggage compartment floor panels and lift out panel. See Fig. 13 . Impact absorber mounting nuts can now be accessed .

3. Rear bumper :

" Remove lower bumper panel as described in Rear bumper, removing and installing . " Remove bumper bracket mounting bolt at impact absorber .

4. Using a 12-inch extension and a l4mm Allen socket, turn adjusting collar clockwise or counterclockwise as needed to change height of adjusting collar. See Fig . 14.

Adjusting collar Impact absorber, 14 mm Allen Socket

~4 Ratchet extension

Ratchet Fig. 13 . Luggage compartment floor panel fasteners (arrows) . (Left side shown. Righf side is similar) 5. Installation ís reverse of removal. Tightening Torques " Bumper bracket to impact absorber (M10 bolt) . . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 ft-lb) " Impact absorber to chassis (M8 nut) . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft-Ib)

Bumper height, adjusting The adjustment procedure given below applies to either the front or rear bumper . A 14mm allen socket is needed to make the adjustment . 1 . Raise and properly support vehicle. WARNING Make sure that the car is firmly supported on jack stands designed for the purpose. Place the jack stands beneath a structural chassis point. Do not place jack stands under suspension parts.

2. Front bumper :

" Remove bumper as described earlier. " Remove bumper bracket bolt . Refer to Fig. 9.

EXTERIOR TRIM

0012073

Fig. 14 . Adjust bumper height at threaded adjusting collar in bumper impact absorber. 5. Reinstall mounting bolts and check bumper height. Refit front bumper. Tightening Torques " Front bumper to bumper bracket (M8 nut) . . . . . . . . . . 22 Nm (16 ft-Ib) " Front bumper bracket to impact absorber (M10 bolt) . . . . . . . . 55 Nm (41 ft-Ib) " Rear bumper bracket to impact absorber (M10 bolt) . . . . . . . . 42 Nm (31 ft-Ib)

EXTERIOR TRIM Much of the exterior trim is retained to the body by plastic clips and fasteners that may be damaged during removal . Be sure to have the necessary fasteners on hand when removing exterior trim pieces .

EXTERIOR TRIM, BUMPERS

510-7

BMW emblem, removing and installing The procedure given below applies to both front and rear emblems. 1 . Wrap and of a screwdriver with tape . CAUTION-

Protect hood paint by covering area around emblem with tape .

2. Carefully pry out emblem . See Fig . 15 .

Fig. 16 . Body sida molding retaining clips (arrows) .

UVI 1'¿.

Fig. 15 . BMW emblem being removed. Pry up emblem carefully on either side (arrows) . Note tape on screwdriver tips . 3. Installation is reverse of removal.

" Replace plastic inserts in body if damaged. " If emblem fits loosely into inserts, use a small amount of body molding tape or adhesiva on rear of emblem before installing .

Body side molding, replacing To remove body side moldings, carefully pry the moldings straight off. See Fig. 16 . Installation is the reverse of removal . Replace any clips or clip covering boots damaged during removal .

Radiator grille, removing and installing 1 . Remove plastic front radiator shroud or air duct, as needed

0013048 Fig. 17 . Radiator grille being tapped inward . Right side front panel top retaining screw is shown at A.

Front panel, removing and installing The front panel is shown in Fig. 18 . 1 . Remove front bumper as described earlier.

2. Lightly tap center of grilla toward radiator and remove from panel opening. Chrome ring pulís out from front. See Fig. 17 .

2. Remove headlights . See 630 Exterior Lighting .

3. To replace, snap grille and chrome piece together . Push assembly into front panel, pressing at top and bottom until it snaps into place.

4. With engine hood open, remove front panel retaining screws at left and right sides of radiator. See Fig. 19 .

3. Remove radiator grille as described earlier.

EXTERIOR TRIM

510-8

EXTERIOR TRIM, BUMPERS

Fig . 18. Front panel assembly. Note top retaining screws (A), retaining screws at radiator support (B), and side retaining screws (C) .

00130~, u

Fig. 19 . Front panel retaining screws at radiator (arrows) . Right side shown . To remove left side screws it may be necessary to remove air filter housing or duct . 5 . Remove front panel top retaining screws near hood latches . Refer to Fig . 17 . 6 . Working under car, remove left and right side panel retaining screws. See Fig . 20 . 7. Remove panel and repair or replace with painted part. 8 . Installation is reverse of removal .

EXTERIOR TRIM

0013145

Fig . 20 . Front bumper must be off to access far right and left front panel retaining screws from below (arrows) . (Right side shown .)

DOOR WINDOWS

512-1

512 Door Windows GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512-1 Front door window, initializing . . . . . . . . . . . . . 512-1

WINDOW SERVICE, 4-DOOR MODELS . . . . . . . . . . . . . . . . . . . . . 512-2 Front door window, removing and installing (4-door models) . . . . . . . . . . . . . . . . . . . . . . 512-2 Front door window, adjusting (4-door models) . . . . . . . . . . . . . . . . . . . . . . 512-3 Rear door window, removing and installing (4-door models) . . . . . . . . . . . . . . . . . . . . . . 512-4 Rear door fixed glass, removing and installing (4-door models) . . . . . . . . . . . . . . . . . . . . . . 512-4

WINDOW SERVICE, 2-DOOR MODELS . . . . . . . . . . . . . . . . . . . . .512-5

Front door window, removing and installing (2-door models) . . . . . . . . . . . . . . . . . . . . . . 512-5 Front door window, adjusting (2-door models) . . . . . . . . . . . . . . . . . . . . . .512-7 Rear vent window or vent latch, replacing (2-door models) . . . . . . . . . . . . . . 512-11

WINDOW REGULATOR SERVICE . . . . . .512-12 Door window regulator and motor, removing and installing . . . . . . . . . . . . . . . . 512-12

GENERAL

Front door window, initializing

This heading covers door glass, window regulator and power window motor repair information . Before proceeding with window repairs, specifically on late cars fitted with front sideimpact airbags, read the procedure through to determine the scope of the repair.

The front door windows incorporate a pinch-protection feature as well as one-touch up/down (1994 and later models). In order for these features to work correctly, the mechanical stop reference point must be re-initialized after repairs are carried out.

The bonded windshield and rear glass are replaced using special adhesives and tools . It is recommended that bonded glass replacement be done by a professional glass installer.

1 . Close door and turn ignition key on . Fully open front window . 2. Fully close front window .

WARNING " Always wear hand and eye protection when workíng with broken glass. " ff a window is broken, all of the glass bits should be vacuumed out of the door cavity. Use a blunt screwdriver to clean out any remaining glass pieces from the window guide rails.

4. Repeat for remaining window. 5. The windows should now be initialized and the antipinch and one-touch up/down functions should be enabled.

CAUTIONff battery power is lost or the battery has been disconnected, windows must be re-initialized. Both one touch up/down and pinch-protection will be inactive until windows are re-initialized. Sea below.

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

512-2

DOOR WINDOWS

WINDOW SERVICE, 4-DOOR MODELS WARNING When servicing the door wíndows, the harness connector to the window regulator should always be disconnected to prevent pinching fingers in closing window. NOTEIf the battery is disconnected, the front window regulator motors must be re-initialized after repairs are carried out. lf the window motors are not reinitialized, the programmed one-touch upldown and anti-pinch functions will be disabled. See Front door window, initializing .

Front door window, removing and installing (4-door modeis) 1 . Lower door window about 12 in . (300 mm) .

0013061

Fig. 1 . Lift off window sea¡ from door. Note metal retainer (arrow) . 2door car shown .

2 . Remove front door panel and vapor barrieras described in 411 Doors . WARNING " Some 1997 and all 1998 cars are fitted wlth sideimpact airbags in the front doors. When servicing the door wíndows on cars with front side-impact airbags, always disconnect the negative () battery cable. See 721 Airbag System (SRS) for cautions and procedures relating to the airbag system . " Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡. 3 . On cars with side-impact airbags, disconnect negative (-) cable from battery. Then remove airbag unit from door. See 721 Airbag System (SRS) . NOTEIn some modeis covered in this manual, it is not essential to remove the side-impact airbag to access internal door components. However, the procedure is recommended forsafety reasons. 4 . Disconnect harness connector from window motor to prevent accidental operation . 5 . Carefully remove window inner sea¡ and pry off metal retainers under sealing lip to prevent scratching glass . See Fig . 1 . 6 . Remove retaining clips from window slides . See Fig . 2 .

WINDOW SERVICE, 4-DOOR MODELS

Fig. 2. Retaining clips for window slides (arrows) .

0011696

7 . While supporting window glass, pry window lifting arms out of left and right slides . See Fig . 3 . 8 . Pivot window up at rear and out of door. 9 . Installation is reverse of removal, noting the following : " Use new mounting bolts when reinstalling the side-impact airbag to the door (where applicable) . See 721 Airbag System (SRS) . " Adjust window as described later . " Re-initialize window regulator motors as described earlier.

DOOR WINDOWS

512-3

3 . Remove front door panel and vapor barrier as described in 411 Doors . 4 . Remove airbag unit from door. See 721 Airbag System (SRS) . NOTEIn some models covered in this manual, it is not essential to remove the side-impact airbag to access interna¡ door components. However, the procedure is recommended for safety reasons.

Fig. 3 .

0011697

5 . Loosen regulator stop at window regulator support. See Fig . 4 .

Window lifting arms shown removed from slides (arrows) .

Front door window, adjusting (4-door models) Whenever the front window or window regulator is removed, window adjustment should be checked . The glass should contact the top of the window squarely and should seat against the window sea¡ uniformly . NOTE If the window does not contact the window seal uniformly, wind noise or water infiltration may result Be sure to re-initialize the window motors as described earlier . WARNING Some 1997and all 1998 cars are fitted wíth side-impact airbags in the front doors . When servicing the door windows on cars with front side-impact airbags, always disconnect the negative () battery cable . See 721 Airbag System (SRS) for cautions and procedures relating to the airbag system .

Fig . 4. Wíndow regulator stop (arrow) .

0013075

6 . If glass is not squarely positioned in window frame, loosen support arm bolt and reposition arm as necessary. Tighten bolt. See Fig . 5 .

CA UTION" In models with side-impact airbags, adjusting the front window requires that the battery cable be reconnected with the side-impact airbag disconnected. This will set a fault code in the SRS control module, turn on the SRS warning light, and disable the SRS system until the fault memory is cleared using special SRS test equipment. " Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii. 1 . Raise door window to top of its travel . 2 . On cars with side-impact airbags, disconnect negative (-) cable from battery.

Fig . 5. Adjust window to its frame by loosening bolt (arrow) and repositioning support arm up or down . WINDOW SERVICE, 4-DOOR MODELS

512-4

DOOR WINDOWS

7. Push regulator stop tightly against window regulator sector and tighten nut. o Check for tight, even fit at top of window frame.

" If necessary, temporarily reconnect negative (-) cable to battery and raise window so it is pressing uniformly against top rubber sea¡ before final tightening . 8. Reinitialize front window motors as described earlier. Tightening Torques " Regulator stop to window regulator . . . . 9 Nm (7 ft-Ib) " Window regulator bracket to door . . . . . 9 Nm (7 ft-Ib)

Rear door window, removing and installing (4-door models)

4. Lower door window about 12 in . (300 mm). Remove window lifting arm retaining clip from window slide. Refer to Fig. 2. WARNINGOnce the window is lowered, dísconnect harness connector from power window motor to prevent accidental operation of the window.

5. Pry lifting arm out of slide. Refer to Fig. 3. NOTE Support window in door before disconnecting lifting arm from window slide .

6. Remove rubber channel from door frame perimeter.

1 . Remove rear door panel and vapor barrier. See 411 Doors . 2. Pul¡ out rubber guide at front of window frame. Remove three screws and pul¡ off exterior trim cover. See Fig. 6.

7. Remove window glass from above. 8. Installation is reverse of removal.

" Rear window adjustment is similar to front window adjustment, given earlier. " Reinitialize window motors as described earlier.

Rear door fixed glass, removing and installing (4-door models) 1 . Remove window from rear door as described earlier. 2. Remove upper and lower bolts at guide rail . Lift up rubber sea¡ to access upper bolt . See Fig . 7.

UJ117U1

Fig. 6. Trim cover mounting screws (arrows) . To remove cover, slide up and off door. 3. Lift up and remove window inner sealing strip. Remove clips at edge of window channel . Refer to Fig. 1 . Fig. 7. Rear guide rail mounting bolts (arrows) .

WINDOW SERVICE, 4-DOOR MODELS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

DOOR WINDOWs 3. Remove guide rail screw at top and move rail aside enough to slide glass forward and out of door frame. See Fig. 8.

512- 5

CAUTION-

" In models with side-impact airbags, removing the front window requires fhat the battery cable be reconnected with the side-impact airbag disconnected. This will set a fault code in the SRS control module, turn on the SRS warning light, and disable the SRS system until the fault memory is cleared using special SRS test equipment. " Removing the front window will upset the adjustment and alignment of the window. Window adjustment, as described later, must be carried out after installation to prevent damaging the glass.

1 . On cars with side-impact airbags, disconnect negative (-) cable from battery.

CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

Fig. 8. Remove guide rail screw (A) and move rail aside. 4. Installation is reverse of removal.

WINDOW SERVICE, 2-DOOR MODELS WARNING -

When servicing the door windows, the hamess connector to the window regulator should always be disconnectod to prevent pinching fingers in closing window.

2-door models are equipped with the "close with door shut" feature. In this rriode, the window glass moves down slightly when the door latch is activated, then goes up tightly against the weather-strip when the door is fullyclosed .

NOTE -

The front window regulator motors must be re-initialized after repairs are carried out. If the window motors are not reinitialized, the programmed one-touch up/down and anti-pinch functions will be disabled. See

Front door window, initializing .

Front door window, removing and installing (2-door models) WARIWNG -

Some 1997and a111998 cars are fitted with side-impact airbags in the front doors. When servicing the front windows on cars with front side-impact airbags, always disconnect the negative (-) battery cable. See 721 Airbag System (SRS) for cautions and procedures relating to the airbag system.

2. Remove interior door panel and vapor barrier. See 411 Doors. 3. Where applicable, remove side-impact airbag from door. See 721 Airbag System (SRS).

NOTE-

In some models covered in this manual, it is not essential to remove the side-impact airbag lo access intemal door components. However, the procedure is recommended for safety reasons.

4. Pull off exterior door molding. See 510 Exterior Trim, Bumpers. 5. Lower door window completely If necessary, temporarily reconnect battery cable. 6. Lift up and remove window inner sealing lip. Remove all metal retainers under sealing lip. See Fig. 9. 7. Raise window to about 10 in . (250 mm). If necessary, temporarily reconnect battery cable. Remove guide bracket mounting nuts and remove bracket. See Fig. 10,

8. Lowerwindow about 4'/2 in . (110 mm) . If necessary, temporarily reconnect battery cable. Working through bore hole in door exterior, remove lower guide bracket through-bolt from glass. See Fig. 11 . 9. Lower window about 2'/2 in . (65 mm). If necessary, temporarily reconnect battery cable. Repeat step 8 to remove upper through-bolt from guide bracket. 10 . Raise window to about 71/2 in . (190 mm) from top. If necessary, temporarily reconnect battery cable. Remove window rear limit stop bracket. See Fig. 12 . WINDOW SERVICE, 2-DOOR MODELS

512- 6

Fig . 9 .

DOOR WINDOWS

0013061

Lift window inner sealing lip from door. Note metal retainer (arrow) .

0013063

Fig . 11 . Using 4mm Allen socket, reach through rear bore hole (A) in door to remove window guide bracket boits . (Exterior door molding has been removed .)

0013065

0013083

Fig . 10 . Window rear guíde bracket nuts A to be removed . Loosen nuts B to allow bracket room to swivel out of the way.

Fig . 12 . To remove rear window limit stop bracket, remove bolt A and loosen clamping bolt B . 11 . Lower window about 41/2 in . (110 mm) . If necessary, temporarily reconnect battery cable . While supporting window, remove retaining clips from window slides and disconnect lifting arms from slides . See Fig . 13 .

WINDOW SERVICE, 2-DOOR MODELS

DOOR WINDOWS

512-7

Fig . 13. Lifting arm retaining clips (arrows) at window slides . 12 . Tip window so rear of glass is up out of door. While supporting window, remove window front limit stop bracket . See Fig . 14 .

Fig . 15 . Correct installation of door top rubber seal .

Tightening Torques " Rear guide bracket to window . . . . . . . 6 Nm (53 in-lb) " Rear guide bracket to roller guide . . . . . . . . . . . . . . . . . . . . . 9 Nm (7 ft-Ib)

Front door window, adjusting (2-door modeis) The "close with door shut" feature of 2-door cars, as well as the frameless window, makeswindow adjustment critical :

0013067

Fig . 14 . With window glass shown partially tipped out of door, remove bolt A and loosen bolt B in order to remove front window limit stop bracket . 13 . Take glass fully out of door . 14 . Installation is reverse of removal, noting the following : " Guide front of window into front guide rail and rest it there while installing front window limit stop bracket. " When installing window rear guide bracket, tighten countersunk screws in glass first (through outside of door), then install guide rail bracket . " Insert rubber sea¡ at top of door correctly See Fig . 15 . " Use new mounting bolts when reinstalling the side-impact airbag to the door (where applicable) . Reset SRS warning light and clear SRS fault memory using special test equipment . See 721 Airbag System (SRS) . " Adjust window as described later. " Re-inítialize window regulator motors as described earlier.

WARNING " Some 1997 and afl 1998 2-door cars are fitted with side-impact airbags in the front doors. When servicing the door windows on cars with front side-impact airbags, always disconnect the negative (-) battery cable. See 721 Airbag System (SRS) for cautions and procedures relating to the airbag system. " Adjusting the front window requires that the battery cable be reconnected with the side-impact airbag disconnected. This will set a fault code in the SRS control module, turn on the SRS warning light, and disable the SRS system until the fault memory is cleared using special SRS test equipment. " There is risk of window glass breakage if correct adjustment procedures are not used. If in doubt, this procedure should be left to a trained BMW technician .

WINDOW SERVICE, 2-DOOR MODELS

512-8

DOOR WINDOWS

NOTE-

To achieve an accurate window adjustment in 2-door models with "close with door shut" feature, simulate a closed door as follows : On early cars, manually turn the latch on the door to the closed position. See Fig. 16 . On later cars, insert a wedge of wood into the striker on the body to close the striker switch. Be sure to open the rotary latch (by pulling up on the door handle) or remove the wedge before closing the door.

A Window insertion depth at A-pillar B B-pillar preload gap (measure gap at 20 mm from top of door) C Window insertion depth at roof line/window parallelism (make measurement at 3 .5 in . and 16 in . from B-pillar edge) 0013076

Fig . 17 . 2-door window adjustment positions .

NOTE-

" In some models covered in this manual, it is not essential to remove the side-impact airbag to access interna¡ door components. However, the procedure is recommended for safety reasons. 0013066

Fig. 16. To manually close door latch, push rotary latch in direction of arrow.

CAUTION-

Do not close the door with the rotary latch in closed position, or with a wedge in the striker.

" After each adjustment step, fully lower and raise window and check adjustment before going on to the next step. " 1f parts of the front window mechanism were replaced, make sure initial adjustments are in the center of their travel range. Once the glass is installed, position glass to the rear guide rail as shown in Fig. 18 . 4 . To set window preload B (See Fig . 1 g .) :

When making adjustments to the front door window, see Fig . 17 . 1 . On cars with side-impact airbags, disconnect negative (-) cable from battery.

CAUTION-

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

2 . Remove interior door panel and vapor barrier . See 411 Doors . 3. Where applicable, remove side-impact airbag from door. See 721 Airbag System (SRS) .

WINDOW SERVICE, 2-DOOR MODELS

" Measure up 20 mm (0 .75 in .) from top of door and mark position on glass . " Close door just until top of glass contacts seal . " Measure gap between glass (at 20 mm mark) and window seal . " If adjustment is necessary, move bottom of window guide in or out to correct . See Fig . 20 . " If further adjustment is needed, move bottom of window in or out by sliding guide bracket . Refer to Fig . 18 .

Preload Gap " B (Refer to Fig . 1 g .) Coupe . . . . . . . . . . . . . . . . . . . . . . . . .8 mm (0 .32 in .) Convertible . . . . . . . . . . . . . . . . . . . . . 3 mm (0 .12 in .)

DOOR WINDOWS

512- 9

Window glass

surface

5tud center

0013153

Fig . 20 . Rear guide rail lower mounting bolts in bottom of door (arrows) . 5 . To set insertion depth A (Refer to Fig . 17 .) : Fig . 18 . Rear guide rail to rear guide bracket initial adjustment . Top should be set at 30 mm (1 .2 in .) from glass to stud center ; bottom should be set at 34 mm (1 .3 in .) from glass to stud center.

Preload B Coupe : 8 mm Convertible: 3 mm

0013081

Fig . 19 . With top of glass against door sea¡ (top arrow), measure preload B at 20 mm (0 .75 in .) above top of door.

" Lower window about 10 in . to access window bracket at rear guide. If necessary, temporarily reconnect battery cable . " Loosen guide rail bracket and/or rear guide rail mounting bolts and reposition window left to right . See Fig . 21 . or Fig . 22 . " Fully close and align window. Check that glass enters window sea¡ to the specification listed . " When adjustment is correct, tighten loosened fasteners .

0013079

Fig. 21 . Loosen nuts on rear guide bracket (arrows) and reposition glass fore/aft . Holes in bracket are elongated to allow for small amounts of adjustment .

WINDOW SERVICE, 2-DOOR MODELS

512- 1 0

DOOR WINDOWS " Raise window . Loosen rear bolt at regulator support arm (5mm Allen wrench). See Fig. 24 . Align window parallel to roof line by moving support arm up or clown. Tighten arm bolt . " Lower window and remove rubber plugs at bottom of door. If necessary, temporarily reconnect battery cable. " Adjust front and rear limit stops so that window retracts into window seal as specified. See Fig. 25 . " Raise window to check adjustment . " Push regulator stop fully forward and tighten bolt . " Close door and check window operation .

0013078

Fig. 22. Move window fore/aft at rear guide rail top mounting bolts (arrows). Insertion Depth " A (See Fig. 17 .) . . . . . . . . . . . .1-1 .5 mm (0 .04-0.6 in .) 6. To set Insertion depth C (Refer to Fig. 17 .) :

0013077

" Lower window slightly. Loosen stop at window regulator motor. See Fig. 23 .

Fig. 24 . Use 5mm Afen socket to loosen mounting bolt at support bracket (arrow) and slide bracket up or clown to adjust window position at roof line . (Allen bolt head faces outside of door.) CAUTION-

" Recheck preload gap B (step 4) . Excessive preload could cause window to shatter. " The fully closed window must not contact the rain gutter when opening the door (in the event the "close with door shut" feature is faulty or the battery is dead).

7. Use new mounting bolts when reinstalling the side-impact airbag to the door (where applicable) . Reset SRS warning light and clear SRS fault memory using special test equipment. See 721 Airbag System (SRS). 8. Replace door panel, rubber door plugs and outside door molding.

Fig. 23 . Window regulator stop (arrow).

WINDOW SERVICE, 2-DOOR MODELS

0013075

9. Re-initialize window regulator motors as described earlier.

DOOR WINDows

512-11

0013070

Fig . 27 . Rear vent latch screws on C-pillar and on window (arrows) . 3 . Remove front seat belt sliding anchor trim at B-pillar (door post), and remove anchor nut . See Fig . 28 .

0013080

Fig . 25 . Reach through door bottom to adjust window limit stops . Rear stop being adjusted .

Rear vent window or vent latch, replacing (2-door modeis) 1 . Remove C-pillar (rear roof pillar) trim . See Fig . 26 .

Fig . 28. B-pillar seat belt anchor trim (arrow) .

úulzoiz

4 . PA off sliding anchor adjustíng knob . Partially pull away door edge and vent window trim strips and remove top B-pillar plastic trim . 5 . Remove seat belt sliding anchor. See Fig . 29 . 6 . While supporting window, remove its B-pillar mounting fasteners . See Fig . 30 .

0013069

Fig . 26. C-pillar trim shown removed . Peel off window sealing trím and then unclip pillar trim piece . Unplug interior light socket (arrow) . 2 . Remove window latch screws at C-pillar. See Fig . 27 .

7 . Installation lowing :

is reverse of removal . Keep in mind the fol-

" Plastic sealing washers must be installed between glass and body on forward glass mounting studs . " Reinstall sealing washers on both sides of glass at rear latch attachment .

WINDOW SERVICE, 2-DOOR MODELS

512- 1 2

DOOR WINDOWS Tightening Torques

" Latch to vent window (M5 screw) . . . . . 6 Nm (53 in-lb) " Seat belt anchor nut . . . . . . . . . . . . . . 31 Nm (23 ft-Ib) " Seat belt sliding anchor mounting bolts . . . . . . . . . . . . . . . . . . 24 Nm (17 ft-Ib) " Vent window to body (M6 nut) . . . . . 6 .2 Nm (55 in-lb)

WINDOW REGULATOR SERVICE Door window regulator and motor, removing and installing This procedure applies to front or rear door windows . 1 . Remove door panel and vapor barrier as described in 411 Doors .

0013071

Fig . 29. Seat belt sliding anchor mounting bolts on B-pillar (arrows) . Note door post and vent window trim strips peeled away.

WARNING " Some 1997 and all 1998 model year cars are equipped with front side-impact airbags in the front doors . Whenever servicing the doors or windows on cars with front side-impact airbags, always disconnect the negative (-) battery cable. See 721 Airbag System (SRS) for cautions and procedures relating to the airbag system. " Prior to disconnectiog the battery, read the battery disconnection cautions gíven at the front of this manual on page vi¡¡. 2 . Remove door glass as described earlier in this section . 3 . Remove inside door handle . See Fig . 31 . 4 . Disconnect wiring connector to power window motor. 5 . Remove regulator mounting bolts or drill out rivets . See Fig . 32 .

0013193

Fig . 30 . Vent window mounting nuts on B-pillar (arrows) .

0013072

Fig. 32. Front window regulator mounting fasteners (arrows) . 6 . Remove regulator assembly from door .

WINDOW REGULA TOR SERVICE

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

0013073

Fig . 31 . Inside door handle . Remove screw A, then unhook from rod B. 7 . Unbolt power window motor from rear of regulator. NOTESome of the window regulators are mounted to the doors with rivets. The rivets must be drilled out. During installation, M6 x 10 bolts and self-locking nuts can be substituted. 8 . Installation is reverse of removal . " Adjust door window as described earlier. " Re-initialize window regulators as described earlier.

Tightening Torques " Window regulator to door . . . . . . . . . . . . 9 Nm (7 ft-Ib) " Window motor to regulator . . . . . . . . . . . 5 Nm (4 ft-Ib)

INTERIOR TRIM

513-1

513 Interior Tri m GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513-1 CENTER CONSOLE . . . . . . . . . . . . . . . . . . . 513-1 Center console, removing and installing . . . . . 513-1

GENERAL This repair group covers interior trim removal and installation procedures . For removal and installation of interior switches, including interior lighting equipment, see 612 Switches and Electrical Accessories. Most of the interior trim and finish paneis are clipped or screwed into place. Many of the trim retaining clips are designed to be used only once . When removing trim that is held in place with clips, it is a good idea lo have spares on hand before beginning the job.

DASHBOARD. . . . . .

. . . . . . . . . . . . . . : . .513-2

Glove compartment, removing ... and installing . .513-2 Lower left dash panel, removing and installing . . . . . . . . . . . . . . . . . 513-2 Dashboard, removing and installing . . . . . . . . .513-3

4. Remove Multi-Information Display module . See 620 Instruments . 5 . Remove hazard warning switch and power window switches by pushing up and out from below. 6. Remove lower left dashboard panel and glove compartment as described later in this repair group. 7. Remove retaining screw under hazard light switch . Pull rear console back and remove retaining nut at back of front console. See Fig. 1 .

CENTER CONSOLE The front section center console houses the Multi-Information Display (MID) module, the front ashtray and cigarette lighter; shifter lever, power window switches and the hazard warning switch . The rear center console section houses the ashtray(s) and covers the emergency brake cable ends .

Center console, removing and installing

1 . Disconnect negative (-) cable from battery and cover terminal with insulating material . CA UTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

2. Remove shifter boot or selector lever cover. See 250 Gearshift t-inkage . 3. Remove rear ashtray retaining screws to take out ashtray. Remove rear console retaining screw under ashtray.

0013154

Fig. 1 . Console retaining screw. 8. Take out rear console first, then front console.

CENTER CONSOLE

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

513-2

INTERIOR TRim

DASHBOARD Dashboard removal is a complex operation, involving disconnection and dismantling of a number of electrical and dash structural components . The BMW E36 is equipped with SRS airbags mounted in the steering wheel, in the dashboard (1994 and later) on the passenger side, and in the front doors (1997 and later) . Airbags units are pyrotechnic devices and should be treated with extreme caution. Improper handling of the airbags could cause serious injury . WARNING " The BMW Supplemental Restraint System (SRS) is complex and special precautions must be observed when servicing. Serious injury may result if system service is attempted by persons unfamiliar with the BMW SRS and its approved service procedures . BMW specifies that all inspection and service should be performed by an authorized BMW dealer. " Before performing any work involving the steering wheel or interior trim in the vicinity of the airbags, disconnect the negative () battery cable. See 721 Airbag System (SRS) . " SRS contains a back-up power supply within the SRS control module. A 10 minute díscharge period should be allowed after the battery cable has been disconnected.

Fig . 2 .

Glove compartment mounting screws (arrows) .

0013107

Lower left dash panel, removing and installing 1 . Remove lower dash panel retaining screws . See Fig. 3.

Glove compartment,

removing and installing 1 . Open glove compartment door. 2. Remove glove compartment mounting screws . See Fig. 2. 3. Pull glove compartment out, disconnecting electrical harness connectors as necessary. 4. Installation is reverse of removal.

Fig . 3. Lower left dash panel retaining screws (arrows) .

0013155

2. Pull lower dash panel left and back to disengage from driver's footwell retaining clips . 3. Installation is reverse of removal .

DASH80ARD

INTERIOR TRIM

513-3

Dashboard, removing and installing 1 . Disconnect negative (-) cable from battery and cover terminal with insulating material . CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡.

2. Remove center console as described earlier. 3. Remove glove compartment as described earlier. 4. Remove lower left dash trim piece as described above. Remove lower right dash trim panel. See Fig. 4.

Fig. 5. Driver side knee bolster mounting bolts (arrows) . 9. Remove headlight switch . Remove turn signal and windshield wiper/washer stalk switches . See 612 Switches and Electrical Accessories. 10 . Remove A/C control head and module . See 640 Heating and Air Conditioning . 11 . Remove radio. See 650 Radio. 12 . Remove A-pillar (windshield pillar) trim on left and right sides . See Fig. 6.

Fig. 4. Lower right dash trim piece retaining screw (arrow). 5. Remove driver and passenger airbags. See 721 Airbag System (SRS). WARNING Store the removed airbags in a safe place. Position the airbags facing up.

6. Remove steering wheel. See 320 Steering and Wheel Alignment . 7. Remove driver side knee bolster. See Fig. 5.

UU13156

Fig. 6. A-pillar (windshield pillar) trim removal. Right side shown, left is similar.

8. Remove instrument cluster. See 620 Instruments.

DASHBOARD

513- 4

INTERIOR TRIM

13 . Remove reinforcement bar below steering column and remove steering column shear bolts. Lower steering only slightly and support steering column . See Fig . 7.

Fig. 7. Reinforcement bar bolts (arrows) . Shear (headless) bolts at steering column will have to be drilled out and replaced duringreinstallation .

Fig. 9. Windshield defroster outlet being lifted off (arrow).

0013157

16 . Remove mounting bolts on left and right ends of dashboard. See Fig. 10 .

WARNING Lower steering column only enough to facilitate removal of the dashboard. The steering column supports and swivel spindles can be damaged if the column is lowered too much .

14 . Remove glove compartment support frame.See Fig. 8.

Fig. 8. Glove compartment support frame bolts (arrows) .

0012643

15 . Carefullypry out defroster outlets (left and right sides) at base of windshield . Remove screw below each outlet. See Fig. 9.

DASHBOARD

Fig. 10. Dashboard mounting bolt (arrows) . Left side shown, right is similar. Some models may have may have two bolts on each side . 17 . Lift instrument panel off slowly, making sure all harness connectors and wiring are disconnected . 18 . Installation is reverse of removal.

CENTRAL LOCKING AND ANTI-THEFT

515-1

515 Central Locking and Anti-Theft GENERAL . . . . . . . . . . . . . . : . . . . . . . . . . . . . 515-1 DOOR HANDLES AND LOCKS . . . . . . . . . 515-1 Front door lock, removing and installing . . . . .515-1 Front door handle, removing and installing . . . 515-3 Rear door lock, removing and installing . . . . . 515-4 Rear door handle, removing and installing . . . 515-5 Door striker, replacing . . . . . . . . . . . . . . . . . . . 515-6 LOCKING ACTUATORS . . . . . . . . . . . . . . . . 515-6 Door Locking Actuator . . . . . . . . . . . . . . . . . . 515-6

GENERAL This section covers repair information for the central locking and the anti-theft systems. Keep in mind that E36 cars are equipped with sophisticated and self-diagnostic electrical systems . When experiencing malfunctions relating lo the central locking or the anti-theft system, it is recommended that the system be diagnosed using the BMW service tester (DIS). This advanced diagnostic tool can usually pinpoint electrical faults quickly and safely . Consult an authorized BMW dealer . NOTE-

Additional general electrical information can be found in 610 Electrical Component Locations and Electri-

cal Wiring Diagrams.

DOOR HANDLES AND LOCKS Front door lock, removing and installing

1 . Remove front door panel and vapor barrier as described in 411 Doors. WARNING Some 1997 and all 1998 cars are fitted with side-impact airbags in the front doors. When servicing the door locks on cars with front side-impact airbags, always disconnect the negative (-) battery terminal. See721 Airbag System (SRS) forcautions andprocedures relating to the airbag system .

2. Raise door window completely

Luggage compartment locking actuator, removing and installing . . . . . . . . . . . . . . . . . 515-6 LOCKING SYSTEM AND ELECTRONIC IMMOBILIZATION . . . . . . .515-7 Central Locking System (ZVM) . . . . . . . . . . . . 515-7 Central Body Electronics (ZKE IV) . . . . . . . . . .515-8 Electronic Immobilization System (EWS) . . . . .515-8 EWS II control module, re lacin 515-10 Ring antenna, replacing . . . . . . . . . . . . . . . . . 515-10 EWS II transmitter/receiver module, replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 515-11

3. On cars with side-impact airbags, disconnect negative (-) cable from battery, then remove airbag module . CA UTION-

Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡.

NOTE-

In some models covered in this manual, it is not essential to remove the side-impact airbag to access intemal door components. However, the procedure is recommended for safely reasons .

4. Disconnect harness connector from window motor to prevent accidental operation. 5. On 4-door cars : Peel back rubber window guide from reas guide rail : Remove guide rail mounting bolt at bottom. Unclip any wiring from guide rail and pull guide rail downward and remove from door. See Fig. 1 . NOTE -

The top of the guide rail is "hooked" to the door sheet metal.

6. Remove inside door handle retaining screw. Disconnect inside handle from linkage and remove . See Fig. 2. 7. Cut wire ties and remove door lock electrical harness connector. Remove door lock mounting screws . See Fig. 3. 8. Working inside door, disconnect outside door handle and lock cylinder linkage from door lock. Remove lock from inside door . See Fig. 4. DOOR HANDLES AND LOCKS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

515-2

CENTRAL LOCKING AND ANTI-THEFT

0013117

Fig. 1 . 4-door cars : Remove lower retaining bolt at base of window rear guide rail and pivot rail out of door.

Fig. 3. Front door lock mounting screws (arrows) .

uu11686

0012685

0013073

Fig. 2. Inside door handle retaining screw (A) Unhook linkage from handle at B.

Fig. 4. Pry out lock linkage (A) from plastic retainer. Lift door lock mechanism slightly to Rmove latching pin from lock gate (B). Door lock mechanism shown removed from door. 9. Installation is reverse of removal, noting the following:

" Install lock mounting bolts with Loctite0 270 or equivalent thread-locker. " Reconnect power window motor harness connector. " Use new mounting bolts when reinstalling the side-ímpact airbag to the door (where applicable) . " Secure wire harnesses with wire ties . " Check function of door lock and window mechanism before reinstalling inner door panel.

Tightening Torques " Door lock to door . . . . . . . . . . . . . . . . . 9 Nm (80 in-lb) " Window guide to door . . . . . . . . . . . . 10 Nm (89 in-lb) DOOR HANDLES AND LOCKS

CENTRAL LOCKING AND ANTI-THEFT

515-3

Front door handle, removing and installing 1 . Close door window completely. 2. Remove front door panel and vapor barrier as described in 411 Doors. WARNING Some 1997 and al] 1998 cars are fitted with side-impact airbags in the front doors. When servicing the door handles on cars with front side-impact airbags, always disconnect the negative (-) battery terminal. See 721 Airbag System (SRS) for cautions and procedures relatíng to the airbag system.

3. On cars wíth side-impact airbags, disconnect negative (-) cable from battery, then remove airbag module . CAUTION-

Prior to disconnecting the battery, read the battery disconnection cautions given at the front of thís manual on page vi¡¡.

0011681

Fig. 5. Insert screwdriver into access hole and push locking plate forward (arrow) to release exterior handle trim .

NOTE-

In some models covered in this manual, it is not essential to remove the side-impact airbag to access internal door components . However, the procedure is recommended for safety reasons .

4. Remove door lock as described earlier. 5. Remove window as described in 512 Door Windows. CA UTION-

On models with side-impact airbags, removinglinstalling the front window requires that the battery cable be reconnected wíth the side-impact airbag disconnected . This will seta fault code in the SRS control module, turn on the SRS warning light, and disable the SRS system until the fault memory is cleared usíng special SRS test equipment.

uu11682

Fig. 6. Door handle retaining pin (A) and lock collar nut (B). Door handle trim shown removed. 10 . Remove door handle from door by angling out of door cavity. Removed door handle assembly is shown in Fig. 7.

6. Pry out access plug in end of door. Use screwdriver through access hole to slide exterior trim locking plate into released position . See Fig. 5. Remove door handle exterior trim piece. 7. Working inside door, remove locking clip for door handle retaining pin and push pin out. 8. Working inside door, disconnect electrical harness connector at door handle . Twist plastic connector bracket to remove from door handle . 9. Working at door exterior, remove handle collar nut while supporting handle . See Fig. 6.

0012684

Fig. 7 . Door handle harness connector (A); retaining pin Iocking clip (B); exterior trim Iocking plate (C). Handle assembly shown removed from door.

DOOR HANDLES AND LOCKS

515-4

CENTRAL LOCKING AND ANTI-THEFT

11 . Installation is reverse of removal. Keep in mind the following :

4. Remove screws mounting bottom of window rear track to door. See Fig. 9.

" Make sure rubber seal for handle is correctly positioned before tightening mounting fasteners. " Install exteriortrim piece and then use a hooked tool to pull locking plate into locked position . Make sure door handle trim contacts body evenly before locking trim in place. " Use new mounting bolts when reinstalling the side-impact airbag to the door (where applicable) . Reset SRS warning light and clear SRS fault memory using special test equipment. See 721 Airbag System (SRS). " Reconnect al¡ harness connectors (including power window motor) before installing door panel . " Secure wire harnesses with wire ties . " Adjust and reinitialize windows. See 512 Door Windows .

Tightening Torque " Collar nut to door handle . . . . . . . . . . 10 Nm (89 in-lb)

Rear door lock, removing and installing 1 . Remove rear door panel and vapor barrier as described in 411 Doors.

Fig. 9. Rear window track lower fasteners (arrows) . 5. Remove window rear track top screw and move track aside. See Fig. 10 .

2. Remove window from rear door as described in 512 Door Windows. 3. Disconnect and remove inside door handle . See Fig. 8 .

0013085

Fig. 10 . Rear window track top screw (arrow). 6. Remove screw from lock button linkage rod retainer. Lift rod out of retaining clip . See Fig. 11 . 7. Disconnect door lock harness connector. 8. Remove door lock screws . See Fig. 12 .

0013073

9. Move lock up slightly to disengage from exterior handle linkage. Remove lock from inside door.

Fig. 8. Inside door handle retaining screw (A) Unhook linkage from handle at B.

DOOR HANDLES AND LOCKS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

CENTRAL LOCKING AND ANTI-THEFT

515-5

Rear door handie, removing and installing

1 . Remove rear door panel and vapor barrier as described in 411 Doors.

2. Remove window from rear door as described in 512 Door Windows. 3. Remove door lock as described earlier.

0011688

4. Pry out access plug in end of door . Use screwdriver through access hole to slide exterior trim locking plate into released position . See Fig. 13 . Remove door handle exterior trim piece.

Fig. 11 . Rear door lock button linkage rod retainer (A), rod retaining clip (B), and harness connector (C) .

Fig. 12 . Rear door lock mounting screws (arrows) .

0011687

10 . Installation is reverse of removal. Keep in mind the following : " Insta¡¡ lock mounting boits with Loctite© 270 or equivalentthread-locker. " Reconnect power window motor harness connector before installing door panel. " Secure wire harnesses with wire ties. " Adjust window as described in 512 Door Windows.

u.]lbbl

Fig. 13. Insert screwdriver into access hole and push locking plate forward (arrow) to release exterior handle trim . 5. Remove door handle mounting screws while supporting handle . See Fig . 14 .

Tightening Torque " Door lock to door . . . . . . . . . . . . . . . . . 9 Nm (80 in-lb)

0011684

Fig. 14. Rear door handle mounting screws (arrows) .

DOOR HANDLES AND LOCKS

515-6

CENTRAL LOCKING AND ANTI-THEFT

6. Remove door handle assembly from inside door. 7. Installation is reverse of removal. Keep in mind the following :

Connectionsto door handle

o _ 0

Attaching pin Lock mechanism 0012082

Tightening Torque " Rear door handle mounting screws . . 10 Nm (89 in-lb)

Door striker, replacing The door striker contains an electrical contact switch . If the switch is faulty, the striker must be replaced . To remove the striker, remove the mounting bolts. Disconnect the harness connectorfrom the striker.

Fig. 15 . Front door lock mechanism and related parts. Rear lock mechanism is similar.

Luggage compartment locking actuator, removing and installing 1 . Raise trunk lid. Remove tool kit and trunk lid trim panel . See Fig. 16 .

NOTE

If the striker backup plate fafls into the body cavlty, it can be retrieved after removing the inside trim from the B-pillar (door-post pillar).

Tightening Torque " Striker plate to body pillar. . . . . . . . . . 28 Nm (20 ft-lb)

LOCKING ACTUATORS Door Locking Actuator The front door lock mechanism and actuator are shown in Fig. 15. The rear door lock and actuator are similar. The lock must first be removed, as described earlier, to replace the actuator. NOTE -

" lfjust one of the central locking drives does not operate, the locking linkage could be frozen orstiff enough to prevent actuaton of the drive. Try remove the finterior door panel and lubricating the locking linkage as the first step. " The actuator is not serviceable and must be replaced if defective .

LOCKING ACTUATORS

0013162

Fig. 16 . Trunk lid trim and tool kit retainíng screws and clips (arrows) .

2. Disconnect actuating rod from lock. See Fig. 17 . 3. lJnplug two wíring connectors from actuator. See Fig. 18. NOTE-

The actuator is adjustable . Matchmark the attaching screws before removal.

4. Remove actuator attaching screws . Pull actuator backwards from behind metal shield to remove . 5. installation is reverse of removal . Align actuator screws with matchmarks during installation .

CENTRAL LOCKING AND ANTI-THEFT

515-7

NOTE-

The central locking system responds to accidents vía an impact (inertia) switch . When this function ís activated, the doors are automatically unlocked and the hazard warning lights and interior lights are turned on. The impact switches are mounted in the left and right footwells behind the speaker grilles .

Central Locking System (ZVM) Different versions of the central locking control have been used in the E36 cars . In early production cars (model years 1992 and 1993), the locking system is controlled through the central locking module . This system is referred to as ZVM. 002262

Fig. 17. Pufl off luggage compartment lock actuating rod in the direction of arrow.

Fig. 18. Luggage compartment actuator wire connectors and attaching screws (arrows) .

LOCKING SYSTEM AND ELECTRONIC IMMOBILIZATION The central locking system uses electrical lock actuators at each door and at the trunk lid. The locking system can be actuated by either front door lock or by the luggage compartment lock . On some 1994 and later cars, an additional remote control key pad can also be used to activate the lock and anti-theft systems.

In this system, three microswitches are operated via the door lock cylinder at each front door. Turning the key approximately 45° (position 1) operates the door locking microswitch . Tuming the keyapproximately 90° (position 2) actuates the double locking microswitch . Tuming the keyapproximately45° in the opposite direction through position 0actuates the unlocking microswitch and deactivates the alarm system (position 3) . See Fig. 19 .

Fig. 19 . ZVM door lock cylinder positíons.

0011762

CAUTION-

Do not engage double locking position with passengers in the car unless the master key is available. The door cannot be opened from outside or inside without the master key.

NOTE-

In case of a discharged battery, the car can still be locked or unlocked using the key.

When the key is tuned to the lock position, a micro-switch signals a central control module to lock all doors, luggage compartment, gas tank flap and, in later convertibles, the glove box lid. Where applicable, this also arms the anti-theft system .

LOCKING SYSTEM AND ELECTRONIC IMMOBILIZATION

515-8

CENTRAL LOCKING AND ANTI-THEFT

Central Body Electronics (ZKE IV)

Electronic Immobilization System (EWS)

Beginning with vehicles produced 9193 (model year 1994), the central locking system was integrated with sunroof and window closure into the Central Body Electronics (ZKE IV) (generation four) system . The control module for this system ís mounted in front of the glove compartment.

The electronic anti-theft system known as EWS was first introduced in January 1994 . The early version of the system uses a starting inhibition module to interrupt the ignition, the fuel injection and the starter motor. This system is activated and deactivated by the central lockíng system . The control module for the system is installed under the left side of the dashboard .

In this system two microswítches are operated via the door lock cylinder at both front doors. Turning the key approximately 45° (position 1) operates the door locking microswitch and activates the alarm system . Holding the key in that position also closes any open windows and the sunroof. Turning the key approximately 45° in the opposite direction through position 0 actuates the unlocking microswitch and deactivates the alarm system (position 2) . See Fig. 20 .

Starting with modeis built since January 1995, E36 cars come equipped with a sophisticated coded electronic immobi lization system called EWS II . For a schematic of the system, refer to Fig. 21 . NOTE The EWS 11 system is also sometimes referred to as the Driveaway Protection System or the electronic immobilization system.

On EWS II equipped cars, the ignition key is embedded with a computer chip and permanently encoded. A primary code is programmed into the key and finto the vehicle itself . A secondary code is changed every time the vehicle is started . If the key code and EWS II control module code do not match, the engine management control module and the starter are disabled. EWS II ignition keys cannot be duplicated . The system is designed to have up to ten keys and only an authorized BMW dealer can provide replacement keys . j

Fig. 20 . ZKE IV door lock cylinder positions.

0011762a

LOCKING SYSTEM AND ELECTRONIC IMM081LIZATION

NOTEft possible to damage the electronic circuítry in the key, rendering if unusable . In that case, a new key should be purchased and initialized by an authorized BMW dealer.

CENTRAL LOCKING AND ANTI-THEFT

515-9

DME

TRANSMITTER/ RECEIVER `I MODULE

CLUTCH SWITCH HALL EFFECT y

DIAGNOSIS "D

`mol 111

IIIII

Fig. 21 . EWS II system .

LOCKING SYSTEM AND ELECTRONIC IMMOBILIZATION

515-10

CENTRAL LOCKING AND ANTI-THEFT

EWS II control module, replacing 1 . Disconnect negative (-) cable from battery. CAUTION-

Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page vüf.

2. Remove glove compartment as described in 513 Interior Trim . 3. Remove EWS II control module harness connector. Pull module out of bracket. See Fig. 22 . NOTE-

The EWS 11 module should be identified with EWS 11 markings.

4. Installation is reverse of removal.

Ring antenna, replacing 1 . Disconnect negative (-) cable from battery. CAUTION-

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

2. Remove lower steering column cover. See Fig. 23 .

Transmitter/ receiver module

Ring antenna

Fig. 22. Location of EWS II components . LOCKING SYSTEM AND ELECTRONIC IMMOBILIZATION

Fig. 23 . Steering column cover retaining screw (arrow).

0012543

3. Remove lower left dash trim panel as described in 513 Interior Trim . 4. Cut off wire ties holding wiring harness to steering column. 5. Gently pry off ring antenna from ignition switch . 6. Unplug ring antenna harness from EWS II transmitter/receiver module as described below. 7. Installation is reverse of removal.

CENTRAL LOCKING AND ANTI-THEFT EWS II transmitterlreceiver module, replacing

515-11

4. Disconnect harness connector from transmitter/receiver module . Unclip module from panel. See Fig. 25 .

1 . Disconnect negative (-) cable from battery. CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

2. Remove lower left dash trim panel and knee bolster as described in 513 Interior Trim .

3. Unclip auxiliary relay panel under steering column and lower it to access relays and harness connectors . See Fig. 24 . 0013035

Fig . 25 . Position of EWS II transmitter/receiver module (A) on left side auxiliary relay panel .

5. Installation is reverse of removal.

Fig. 24 . Lowering the left side auxiliary relay panel .

0013164

LOCKING SYSTEM AND ELECTRONIC IMMOBILIZATION

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SEATS

520-1

520 Seats GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 520-1 FRONT SEATS . . . . . . . . . . . . . . . . . . . . . . . . 520-1

Front seat, removing and installing . . . . . . . . 520-1 ' Manual Front Seat Assembly . . . . . . . . . . . . . 520-3 Power Fronf Seat Assembly . . . . . . . . . . . . . ; 520-4

REAR SEATS . . . . . . . . . . . . . . . . . . . . . . . . . 520-5

Rear seat cushion and backrest, removing and installing (fixed seat back models) . . . . . . . . . . . . . . . . 520-5 Rear seat cushion and backrest, removing and installing ( fold-down sean back models ) . . . . . . . . . . . . 520-5 Rear seat backrest side section, removing and installing (fold-down seat back models) . . . . . . . . . . . .520-6

GENERAL This repair group covers removal and installation of the front and rear seats.

FRONT SEATS The front seats installed in E36 cars come in either manual or electrically powered versions . Cloth, vinyl and leather versions are offered. M3 sport seats have extra bolsters on the sides of the sean-back, a thigh support bolster, and extra controls for sean inclination. Seat removal and installation is similar for all versions . Seat disassembly differs in details among the many models of seats.

Front seat, removing and installing 1 . Move seat to fui¡ forward position and raise it as far as possible . Remove two mounting bolts at rear of sean rails . See Fig. 1 . 2 . Move seat to fui¡ rear position, keeping it raised . 3. Disconnect negative (-) cable from battery. CAUTIONPrior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii.

Fig. 1 . Front seat rear mounting bolts (arrows) . 4. Remove plastic caps from front mounting nuts, and then remove mounting nuts . See Fig. 2. WARNING Deactivate front seat belt lock tensioners before proceeding to next step. See 720 Seat Belts . NOTEUse a blanket to protect door sill from scuffing by sean rail during seat removal.

FRONT SEATS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

520-2

S EATS

Fig. 2. Front seat front mounting nut (arrow).

5. On 2-door cars: unhook seat belt from guide on seat back . 6. Tilt seat back to access and unplug electrical harness connectors . Cut or untwist wire ties as necessary. 7. On 4-door cars : Unbolt seat belt from seat frame. See Fig. 3. 8. Remove seat from car.

0013216

0013166

Fig. 3. Seat belt mounting bolt (arrow). 9. Installation is reverse of removal. Keep the following in mind : " Use wire ties or equivalent means to keep seat har ness wiring from being exposed to fraying. " Reactivate front seat belt locks. " Start all seat mounting boits. " Tighten seat mounting fasteners in thís sequence : inner front; outer front; inner rear, outer rear. Tightening Torque " Front seat to floor . . . . . . . . . . . . . . . 55 Nm (41 ft-Ib)

FRONTSEA TS

SEATS

520-3

Manual Front Seat Assembly The non-power seat in E36 cars is shown disassembled in Fig . 4. Component replacement is possible once the seat has been removed from the vehicle as described earlier.

1 . Backrest padding 2. Backrest frame 3. Backrest release lever (two-door)

4. Seat adjustment controis 5. Seat adjustment cables 6. Seat tilt control (M3 only)

7. Seat frame 8. Seat cushion 9. Knee bolster (M3 only)

Fig . 4. Construction of non-power front seat.

FRONT SEATS

520-4

SEATS

Power Front Seat Assembly The power seat in E36 cars is shown disassembled in Fig . 5 . Component, actuator and drive cable replacement is possible once the seat has been removed from the vehicle as described earlier.

1. 2. 3. 4. 5.

Backrest frame Seat frame Backrest release lever (two-door) Backrest release lever cable Lumbar support (from 9/94)

Fig . 5 . Construction of power front seat .

FRONT SEATS

6 . Lumbar support (to 9/94) 7 . Vertical adjustment (rear) 8 . Backrest adjustment gearbox 9 . Backrest adjustment motor 10. Wiring harness

11 . Seat track 12. Seat tilt motor 13 . Tilt motor gearbox 14 . Forward/backward driveshafts 15. Forward/backward motor

SEATS REAR SEATS Rear seat cushion and backrest, removing and installing (fixed seat back modeis)

520-5

2. Remove bottom seat belt anchor belts. See Fig. 7.

NOTE-

Be sure to note relative positions of metal belt-end anchors in order to reassemble correctly.

1 . Pull front of bottom cushion up and out of clips.

NOTE-

Remove rear headrests, if equipped.

2. Fold down center armrest and remove belts from behind arm rest . 3. Slide seat back up off holders. Then slide to side lo clear seat belts. See Fig. 6.

00131b!

Fig. 7. Rear seat belt anchor bolt under rear seat cushion (arrow).

3. Tilt backrests forward and unclip plastic cover. See Fig. 8.

Fig. 6. To remove rear seat, remove bottom cushion . Remove belts (A) behind center armrest. Slide seat back up off holders, then forward.

Rear seat cushion and backrest, removing and installing (foid-down seat back modeis) 1 . Pull front of bottom cushion up and out of clips.

NOTE-

Remove rear headrests, if equipped.

t; Fig. 8. Rear seat back mounting cover plate at base of seat back.

REA R SEA TS

520- 6

SEATS

4. Push spring-loaded lock back and unclip seat back . See Fig. 9.

Rear seat backrest side section, removing and installing (foid-down seat back modeis) 1 . Pull front of cushion up and out of clips. 2. Fold down rear seat backrest . 3. Lift backrest side section up and out. See Fig . 10 .

Fig. 9. Push spring-loaded clip back (arrow).

UU13117

5. Installation is reverse of removal. Make sure backrest locks at top seat belt connection .

0013175

Fig. 10 . Remove backrest side section by lifting out (A) and up (B). 4. Installation is reverse of removal.

1 #=am

REA R SEA TS

SUNROOF

540-1

540 Sunroof GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540-1 SUDE-TILT SUNROOF . . . . . . . . . . . . . . . . . 540-2

GENERAL The electrically-operated slide-tilt sunroof is controlled by a set of cables that move the sunroof panel along guide rails when the motor is operated . The sunroof can be adjusted without removing it from the car. Replacement of the sunroof liner or components such as the cable assembly require that the sunroof panel be removed.

Sunroof panel, emergency closing . . . . . . . . . .540-2 Sunroof panel, adjusting . . . . . . . . . . . . . . . . .540-2 Sunroof motor, removing and installing . . . . . .540-3

NOTE" Be sure to check the drains in the front comers of the sunroof carrier if water ls entering the car through the headliner.

. Removal and repair of the sunroof and other compo-

nents inside the roof cavity is beyond the scope ot this manual.

The components of the slide-tilt sunroof are shown in Fig. 1 .

1 . Sunroof panel 2. Wind deflector 3. Frame 4. Drain

5. Cable 6. Motor 7. L]ner 8. Lever

9. Lever 10 . Sea¡ 11 . Center rail 12 . Sea]

Fig. 1 . Slide-tilt sunroof assembly.

GENERAL

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540-2

SUNROOF

SLIDE-TILT SUNROOF

NOTEThe hex key formanually (emergency) closing the sun-

Sunroof panel, emergency closing

1 . Remove access panel from below sunroof motor. See Fig. 2.

roof can be found in the tool kit located in the luggage compartment.

Sunroof panel, adjusting The sunroof panel should be adjusted whenever the top of the closed sunroof becomes misaligned with the roof of the car, if it does not Glose squarely, if there are wind noises at speed, if there are water leaks, or if the sunroof has been removed. 1 . Open sunroof slightly. Rear of sunroof should be 2 to 3 mm below surface of roof. 2 . Slide sunroof liner slowly and carefully back into roof cavity as far as possible . See Fig. 4.

Fig. 2. Sunroof motor access cover being pried off.

0011816

2. Insert hex key into drive in sunroof motor and turn hex key to Glose panel. See Fig. 3.

Fig. 4. Slide sunroof liner back into roof cavity. 3. Shut sunroof fully.

0~i18r7

Fig. 3. Use hex key to manually Glose sunroof. Turn hex key to mahually Glose sunroof.

CAUTION Do not open sunroof with liner in this position. Damage to sunroofmechanism could result.

SLIDE-TILT SUNROOF

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SUNROOF 4. Rear adjustment: Loosen rear adjusting wedges and push in or out until rear of sunroof is aligned correctly with roof-top . See Fig. 5.

540-3

NOTEUse Loctite® 270 or an equivalent thread sealing compound when reinstalling the retaining screws . Alternatively, install new screws .

6. Open sunroof slightly. Rear of sunroof should be 2 to 3 mm below surface of roof . 7. Slide sunroof liner slowly and carefully forward out of roof cavity as far as possible . Sunroof Height Adjustment Specifications " Rear . . . . . . . . . . . . . .flush/1 mm higher than roof top " Front . . . . . . . . . . . . . . . flush/l mm lower than roof top 0013103

Fig. 5. Adjust rear of sunroof by loosening nuts 1 and 3. Push adjustíng wedges 2 in or out to achieve correct height . NOTE" Push sunroof forward before retightening wedge fasteners. " Use Loctite®270 oran equivalent thread sealing compound when reinstalling the retaining fasteners. Alternatively, install new fasteners.

5. Front adjustment : Loosen retaining screws, then push front of sunroof panel up or down until it is aligned correctly with roof-top . Retighten screws . See Fig. 6.

Tightening Torque " Front or rear adjusting fasteners. . . . . . 6 Nm (53 in-lb)

Sunroof motor, removing and installing The sunroof should be in the closed posítion before removing or installing the sunroof motor. If necessary, manually close the sunroof panel as described under Sunroof panel, emergency ciosing. 1 . With ignition switch off, Rmove access panel from below sunroof motor. Refer to Fig. 2. 2. Remove sunroof motor mounting screws . See Fig. 7.

0013170

Fig. 6. Adjust front of sunroof by loosening screw (arrow). Push sunroof up or down to achieve correct height .

0011825

Fig. 7. Sunroof motor mounting screws (A and B) . Screw at A is longer than screws at B.

SLIDE-TILT SUNROOF

540- 4

SUNROOF

3. Disconnect harness connector from motor and remove motor. 4. Installation is reverse of removal. Be sure the motor is in the "closed" position before installing it to the sunroof carrier. See Fig. 8.

NOTEOn cars manufactured from mid-1994, the sunroof motor gear assembly is encased and cannot be seen . Before installing the motor in the roof, connect electrical harness connector, operate switch to rear until motor stops, then to front until motor stops. Then install motor in roof.

Tightening Torque " Sunroof motor to motor carrier . . . . . 2.8 Nm (25 in-lb)

0011813

Fig. 8. Sunroof motor in "closed" position . Hole (arrow) in large gear aligns with shafts on both gears (to mid-1994) .

SLIDE-TILT SUNROOF

CONVERTIBLE TOP

541-1

541 Convertible Top GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541-1 MANUAL CONVERTIBLE TOP . . . . . . . . . . 541-1 Visor Latch Plate . . . . . . . . . . . . . . . . . . . . . . . 541-1 Visor Latch . . . . . . . . . . . . . . . . . . . . . . . . . . .541-1 Convertible Top Lid Release Mechanism . . . . 541-2 Convertible top and frame, replacing . . . . . . . 541-2 POWER CONVERTIBLE TOP . . . . . . . . . . . 541-2 Front Latching Mechanism . . . . . . . . . . . . . . . 541-4

GENERAL The convertible top comes in three versions : a manually operated top, a semi-automatic power top and a fully automatic power top.

Visor Latch Plate . . . . . . . . . . . . . . . . . . . . . . .541-4 Visor Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541-4 Visor Latch Motor. . . . . . . . . . . 541-5 Convertible top and frame, . . . . . replacing . . . . . . . . . . . . . . . 541-5 Convertible top drive motor, replacing . . . . . . 541-7 Convertible Top Emergency Operation . . . . . .541-7 Convertible Top Lid . . . . . . . . . . . . . . . . . . . . . 541-9 ROLLOVER PROTECTION SYSTEM . . . . 541-9

" Loosen bolts " Latch top " Align top " Retighten bolts. See Fig. 1 .

NOTEThe convertible top control module (CVM) is located behind the left rear side trim panel. For the location of other convertible top electric components see 610

Electrical Component Locations.

The rear window in the convertible models is made of a strong, flexible vínyl which is available separately. Replacement of the rear window is not covered in this manual . BMW has designed a special battery tray forthe convertible which, in conjunction with the mass of the battery in the luggage compartment, serves to dampen convertible body flex ing and vibration . CAUTION-

The E36 convertible requires a special battery which is designed for constant vibration . A battery not designed for this will fa¡¡ much earlier.

MANUAL CONVERTIBLE TOP Visor Latch Plate

Fig. 1 . Visor latch plate is held to top of windshield with three bolts (arrows) .

Visor Latch Check for ease of release and locking of convertible top front latches . Height of a latch can be changed by using the adjusting screw. To change latch tension, it is necessary to remove the trim on the front bow of the top. The ball-joint pull-rod length can then be adjusted . Lubricate latch if necessary. See Fig. 2.

The left and right visor latch plates can be accessed by removing the trim and moldings around the sides and top of the windshield . Each latch is secured to the top of the windshield using three bolts. Latch position is adjusted as follows:

MANUAL CONVERTIBLE TOP

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

541-2

Fig . 2 .

CONVERTIBLE TOP

Manually operated front latch . Loosen mounting nuts (A) and locknut (B), then adjust latch height with hex-bolt (C) . (Fully automatic front latch height adjuster is similar.) Latch tension ís adjusted at rod ball-joint end (D) .

Convertible Top Lid Release Mechanism The convertible lid release handle is situated in the trim panel behind the driver's seat . To remove the handle, pull its plastic insert forward and remove the trim insert . The handle is mounted with a single screw .

Fig. 3. Mounting nuts (A) for convertible top (two on each side) . There is also a horizontal bolt with spacers on each side (B) .

A bowden cable is routed from the handle to the left lid latch . Another cable is routed from the left to the right latch inside the luggage compartment . It is accessed by pulling down the trim lining off the front wall of the compartment .

Convertible top and frame, replacing 1 . Open convertible top partially. Open convertible top lid . Open back windows .

I~I~KX

2 . Remove fasteners in compartments behind door posts and lift out complete top . Count number of shims on horizontal mounting bolts . See Fig. 3 . 3 . Installation is reverse of removal . Be sure to replace Ushaped shims on horizontal mounting bolts . See Fig . 4 . 4 . To adjust position and fit of top, remove or add Ushaped shims until top is properly aligned . Tighten nuts and screws .

POWER CONVERTIBLE TOP The semi-automatic top, installed in 1996 convertibles, must first be manually released from the visor latch plates and pushed back past the "tension point," wheréupon, the automatic retracting motor and linkage take over and pull it into the storage compartment behind the back seat .

POWER CONVERTIBLE TOP

0012754

Fig . 4 .

Horizontal positioning bolt (A) and U-shaped adjusting shims (B) for convertible top. One of two main mounting nuts (ar rows) also visible .

The fully automatic top, standard on 1997 and later convertibles, allows complete operation of the top, from fully open to fully closed, with the push of a toggle switch on the console . The top switch incorporates a "top unlatched" warning LED .

A schematic representation of the fully automatic convertible top is shown in Fig. 5 .

CONVERTIBLE TOP

541-3

KL 30

CONVERTIBLE BATTERY

DOWN

(ON TOP MOTOR) S2

EM TOP n

-I (ON TOP MOTOR)

~ llí9 .1

(IN TOP STORAGE WELL) S4

(ON TRUNK LOCK)I

E36 AUTOMATIC CONVERTIBLE TOP CONTROL MODULE

I LH SIDE TOP LATCH DRIVE) 1

-----------

M-4m íA 7--Offi-

1 I

Íl

FRONT LATCH MOTOR '

I I I I

1 I L--------- J

ENSOR

ít~~ O

HARD TOP LOCK SIGNAL

1~~11 :iq

TOP LID MOTOR

SIGNAL TOP MOTOR POSITION SIGNAL

Fig. 5. Semi-automatic and fully automatic convertible top system . Main additional components in fully automatic top shown inside dashed lines. POWER CONVERTIBLETOP

CONVERTIBLE TOP

541-4

a Folding roof

Frontlatches Convertible top frame

Manual front latch handle

8 e1

Horizontal positioning ~~bolt O

Fig. 6.

Lower mounting pata

0012756

Visor latch plata

Mechanical components of E36 convertible top. Manual, semi-automatic, and fully automatic tops have similar mechanical construction .

NOTE-

The electronic circuits used to control convertible top operation are complex. Diagnosis of the convertible top and the Rollover Protection System are beyond the scope of this book. Your authorized BMW dealer has the proper diagnostic equipment and tools to carry out these tasks.

Front Latching Mechanism A close, tight fit between the front bow of the convertible roof and the top of the windshield is critical for preventing moisture and wind noise from intruding into the passenger compartment.

Visor Latch Plate The left and right visor latch plates can be accessed by removing the trim and moldings around the sides and top of the windshield . Each latch is attached to the top of the windshield using three bolts. Latch position is adjusted as follows: " Loosen bolts Latch top " Align top " Retighten bolts. See Fig. 7.

0012768

Fig. 7. Visor latch plate is held to top of windshield with three bolts (arrows) .

Visor Latch The semi-automatic and the fully automatictopfront latches are of similar design . For the automatic latching mechanism an additional motor has been installed in the front bow of the convertible top. This releases the top from the visor latch plates and pulís it back far enough for the main retracting mechanism to complete the job. The latches and the motor can be accessed by removing the front cover trim from the convertible top.

POWER CONVERTIBLE TOP

CONVERTIBLE TOP

541-5

The left latch in the fully automatic version has two microswitches (S7 and S8) which signal open, closed and latched states . See Fig. 8. The length of the dead center point rod is critica¡ lo correct opening and latching of the convertible top. See Fig. 9. Dead Center Point Rod " Dimension A . . . . . . . . 205.5 f 1 mm (8 .09 t 0.04 in)

Visor Latch Motor The fully automatic convertible top is latched and unlatched by one electric motor installed in the front roof bow. To replace, remove front cover trim from the roof . Remove electrical harness connectors from motor, and remove mounting screws . Slide the motor off the output shafts to the left and right latches. During reinstallation, the output shafts must be tumed until the S8 microswitch in the left latch is tripped.

Convertible top and frame, replacing 1 . Open convertible top partially. Open convertible top lid. Open back windows.

Fig. 9. Preset length of dead center point rod.

2. Fully automatic power convertible top: Remove front cover trim from top. Disconnect electrical harness connectors from front latch motor. Disconnect connectors from S7 and S8 microswitches at left latch.

Motors M1 Convertible top M2 Convertible top lid M3Front latch (fully automatic top) Microswitches S1 & S2 In convertible top motor S3 In convertible top storage compartment S4 In top linkage (semi-automatic only) S5 In luggage compartment latch S6 In right convertible top lid latch S7 & S8 In left conv. top latch (fully automatic)

Fig. 8. Location of automatic and semi-automatic convertible latch mechanisms, motors and microswitches .

POWER CONVERTIBLE TOP

541-6

CONVERTIBLE TOP

3. Remove headliner, starting from front and working backward. Note arrangement and lacing of tensioning cable so it can be reinstalled in its original configuration . See Fig. 10 .

7. Remove fasteners in bottom of storage compartments behind door posts and lift out complete top. Note num ber of shims on horizontal mounting bolt . See Fig. 12 .

0012748

Fig. 10 . Headliner tensioning cable and some of its retaining eyelets (arrows) . 4. Disconnect electrical harness connector from S4 microswitch in middle linkage of convertible top. 5. Disconnect electric motor linkage rods in convertible top storage compartment behind left rear seat . See Fig.

8. Installation is reverse of removal . Be sure to replace Ushaped shims on horizontal mounting bolts. See Fig. 13 .

0012754 Vizib1

Fig. 13 . Horizontal positioning bolt (A) and U-shaped adjusting shims (B) for convertible top. One of two main mounting nuts (arrows) also visible.

6. Pull electrical harness through to disengage from top.

9 . To adjust position and fit of top, Rmove or add Ushaped shims until top is properly aligned. Tighten nuts and screws .

Fig. 11 . Convertible top linkage rods (arrows) in compartment behind left rear seat .

POWER CONVERTIBLE TOP

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

CONVERTIBLE TOP Convertible top drive motor, replacing 1 . Open convertible top partially, stopping when convertible top lid is fully upen . Remove lid . 2. Release luggage compartment lock-out by pressing on microswitch in right convertible top lid latch. See Fig. 14 .

0012745

Fig. 14 . Right side convertible top lid latch . Arrow points to location of luggage compartment lock-out microswitch . 3. Open luggage compartment. Remove trim and inner lining from left side of compartment. 4. Disconnect electrical harness connectors at top motor. Release emergency release cable from lever. Push lever up to release motor. See Fig. 15 .

541-7

5. Working in convertible top storage compartment behind driver's seat, remove convertible top linkage rods from top of motor. Refer to Fig. 11 . 6. Remove four fasteners holding motor to body and remove motor through luggage compartment. See Fig. 16 .

0012761

Fig. 16 . Convertible top motor mounting screws (arrows) . Gasket (A) must be renewed when motor is replaced . 7. Installation is reverse of removal. Keep the following in mind : " Replace sealing gasket between top of motor and body. " Secure motor mounting screws with Locktite® 270 or equivalent . Tightening Torque " Convertible top motor to body mounting screws . . . . . . . . . . . . . . . . . 10 Nm (7.5 ft-Ib)

Convertible Top Emergency Operation A malfunction in the electrical system or another fault in the convertible top mechanism can cause the automatic or semiautomatic top to be stuck in open, shut, or intermediate position . The following general procedures are suggested in order to close the top in an emergency situation. Resetting procedures for convertible top synchronization after emergency closure are beyond the scope of this manual .

uu12759

Fig. 15 . Convertible top motor (A) and release lever (B) in luggage compartment.

Main Motor. To release the top linkage from the motor, lift the left comer of the rear seat to access emergency release handle . See Fig. 17 .

POWER CONVERTIBLE TOP

541- 8

CONVERTIBLE TOP

0012762

Fig . 18 . Remove plastic cover from center of convertible roof front bow to access latching motor drive . 0012764

Fig . 17. Convertible top motor emergency release handle under rear seat. Pull in direction of arrow to release top .

CAUTION-

In case of failure of the automatic or semi-automatic convertible top function, only use the emergency procedure to close the top, never to open it. An authorized BMW dealer should then be consulted.

It is then possible to push the top manually to a near closed position . In the case of the semi-automatic top, simply attach and lock the front latches . Front Latches . Once the fully automatic convertible top has been released from the motor and manually pushed to near-closure, emergency latchíng of the top is possible by using the S-shaped hex key provided in the emergency tool kit . First, remove the plastic cover over the latch motor in the front bow of the convertible top . See Fig . 18 . Next, use the hex key from tool box to crank the front latches shut. See Fig . 19 . Luggage Compartment Cover . A microswitch in the right convertible top lid latch prevents the luggage compartment from being opened while the lid is up . This lockout can be overridden by pressing on the microswitch . Refer to Fig . 14 .

POWER CONVERTIBLE TOP

Fig . 19 . Using emergency hex key to move front part of convertible top .

CAUTION-

The convertible top lid and the luggage compartment cover interfere with each other and cannot be open at the same time. To avoid damage to painted surfaces, an assistant should keep the lid down until the luggage compartment cover can be closed.

CONVERTIBLE TOP

541- 9

Convertible Top Lid The components of the convertible top lid are shown in Fig . 20 .

0012744

Fig. 21 . Construction of the rollover protection cassette .

Fig. 20 . Components of the convertible top lid. The lid latches are cable operated by a drive motor located in the left side of the luggage compartment, behind the trim liner . The same motor is used to raise and lower the lid during automatic convertible top operation. The latch cables must be adjusted so that the lid fits snugly againstthe body when locked . The lid drive motor can be removed and replaced from the luggage compartment.

ROLLOVER PROTECTION SYSTEM

After deployment, the detent pawl in a rollover protection cassette can be retracted using the special tool in the tool kit, fitted to the screwdriver handle . The rear seat headrest needs to be raised for this procedure. WARNING Ensure that the area above and adjacent to the rollover bars remains clear and unobstructed at all times .

CAUTION-

" It is not possible to close the convertible top with the rollover bars extended. " If a hardtop is mounted, be sure to install the protective rollover bar covers provided with the hardtop to prevent damaglng the rear window in case of deployment.

Two spring-locaed cassettes are mounted behind the rear seat. A single rollover sensor, mounted on the left cassette, signals the convertible top module (CVM) of an imminent rollover, whereupon the module triggers both cassettes within 3j10th of a second . See Fig. 21 . Once the cars ignition has been switched on, the rollover sensor performs a self-test lasting 6 seconds. During this time a yellow warning light is lit on the dashboard. If the warning light fails to go out after6 seconds, this means that a fault has been detected in the system . The fault is stored in the CM Faults can be retrieved and diagnosed by special diagnostic equipment. NOTE-

Diagnosis of the convertible top and the Rollover Protection System are beyond the scope of this book. Your authorized BMW dealer has the proper diagnostic equipment and tools to carry out these tasks.

ROLLOVER PROTECTION SYSTEM

ELECTRICAL SYSTEM-GENERAL

600-1

600 Electrical System-General GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-1 Voltage and Polarity . . . . . . . . . . . . . . . . . . . . 600-1 Ming, Fuses and Relays . . . . . . . . . . . . . . . . 600-1 Electrical System Safety Precautions . . . . . . . 600-1 Electrical Test Equipment . . . . . . . . . . . . . . . . 600-2 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . 600-2 Ming Codes and Abbreviations. . . . . . . . . . . 600-2 ELECTRICAL TROUBLESHOOTING . . . . . 600-3 Voltage and Voltage Drops . . . . . . . . . . . . . . . 600-4

Voltage, measuring . . . . . . . . . . . . . . . . . . . . . 600-4 Voltage drop, testing . . . . . . . . . . . . . . . . . . . . 600-4 Continuity, checking . . . . . . . . . . . . . . . . . . . . . 600-5 Short Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 600-5 Short circuit, testing with ohmmete'r . . . . . . . . . 600-6 Short circuit, testing with voitmeter . . . . . . . . . 600-6 TABLES a. Terminal and Circuit Numbers . . . . . . . . . . . . . . . . .600-3

GENERAL

Electrical System Safety Precautions

A brief description of the principal parts of the electrical system is presented here . Also covered here are basic electrical system troubleshooting tips .

Please read the following warnings and cautions before doing any work on your electrical system .

Voltage and Polarity The vehicle electrical system is a 12-volt direct current (DC) negative-ground system . A voltage regulator controls system voltage at approximately the 12-volt rating of the battery. Al¡ circuits are grounded by direct or indirect connection to the negative (-) terminal of the battery. A number of ground connections throughout the car connect the wiring harness to chassis ground . These circuits are completed by the battery cable or ground strap between the body and the battery negative (-) terminal .

Wiring, Fuses and Relays Nearly all parts of the wiring harness connect to components of the electrical system with keyed, push-on connectors that lock into place. Notable exceptions are the heavy battery cables and the starter wiring . The wiring is color-coded for circuit identification . With the exception of the battery charging system, most electrical power is routed from the ignition switch or the battery through the main fuse/relay panel, located in ¡he left rear comer of the engine compartment. Fuses are color coded to indicate current capacities .

WARNING " The cars covered by this manual are equipped with a Supplemental Restraint System (SRS) that automatically deploys one or more airbags. Each airbag unit houses an explosive powerful charge. Any work involving the SRS system should only be performed by an authorized BMW dealer. Making repairs without the proper knowledge and special test equipment may cause serious personal injury. See 721 Airbag System (SRS). " The ignition system of the car operates at lethal voltages . People with pacemakers or weak hearts should not expose themselves to the ignition system . Extra caution must be taken when working on the ignition system or when servicing the engine while it is running or the key is on . See 120 Ignition System for additional ignition system warnings and cautions. " Before operating the starter without starting the engine (as when making a compressfon test), disable the ignition system as described in 120 Igni-

tion System .

" Keep hands, clothing and other objects clear of the electric radiator coollng fan when working on a warm engine . The fan may start at any tíme, even when the ignition is switched off.

The relays and control units/modules are mounted in various places throughout the vehicle. See 610 Electrical Component Locations.

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

600-2

ELECTRICAL SYSTEM-GENERAL

CAUTION " Always turn off the engine and disconnect the negative () cable from the batterybefore removing any electrical components. Disconnecting the battery may erase fault code(s) stored in control module memory. Check for fault codes using special BMW diagnostic equipment. " Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page 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 running. " Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 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 use a test famp that has a normal incandescent bulb to test circuits contafning electronic components . The high electrical consumption of 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 sensitive. 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 connector or relay terminals. " Always switch a digital multimeter to the appropriate function and range before making test connections . " Do not try to start the engine of a car which has been heated above 176°F (80°C), (for example, in a paint drying booth). 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 anytime the ignition is switched on.

WIRING DIAGRAMS

Electrical Test Equipment Many of the electrical tests described in this manual call for measuring voltage, current or resistance using a digital multimeter (DMM) . Digital meters are preferred for precise measurements and for electronics work because they are generally more accurate than analog meters . The numerical display is also less likely to be misread, since there is no needle 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 any two test-points in a circuit . CA UTION" Choose test equipment carefully. Use a digital multimeter with at leadt 10 megaohm input impedance, or an LED test light. An analog meter (swing-need1e) ora test light with a normal incandescent bulb may draw enough current to damage sensitive electronic components . " An ohmmeter must not be used to measure resistance on solid state components such as control units or time delay relays. " Always disconnect the battery before making resístance (ohm) measurements on the circuit.

WIRING DIAGRAMS The wiring diagrams shown in Electrical Wiring Diagrams have been specially designed to enable quick and efficient diagnosis 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 abbreviated . 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 .

ELECTRICAL SYSTEM-GENERAL NOTE Sometimes the color of en installed wire may be different than the one on the wiring diagram. Don't be concerned. Just be sure lo confirm that the wire connects lo the proper terminals.

Wire color codes " BLU . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . Blue " BRN . . . . : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brown " YEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yellow " GRN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . creen " G RY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray " ORG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Orange " RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Red " BLK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black " VIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Violet " WHT . . . . . . . . . . . . . . . . . . . : . . . . . . . . . . . . . . White Most terminals are identified by numbers on the components and harness connectors . The terminal numbers for major electrical connections are shown in the diagrams . Though many terminal numbers appear only once, severa¡ other numbers appear in numerous places throughout the electrical system and identify certain types of circuits . Some of the most common circuit numbers are listed below in Table a. Table a. Terminal and Circuit Numbers Number

1 Circuít description

j Low voltage switched terminal of coi¡

1 High voltage center termina¡ of coi¡

Originates at ignition switch . Supplies power when the ignition switch is in the PARK, RUN, or START position

Originates at ignition switch . Supplies power when ignition switch is in RUN or START position

Battery positive (+) voltage. Supplies power whenever battery is connected. (Not dependent on ignition switch position, unfused)

1 Ground, battery negative (-) terminal

Supplies power from battery to starter solenoid when ignition switch is in START position only

+54

Originates at ignition switch . Supplies power when ignition switch is in the RUN position only

1 Ground side (-) of relay coil

1 Power-in side (+) of relay coil

1 Relay actuated contact

600- 3

Additional abbreviations shown in the wiring diagrams are given below. Abbreviations " ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . antilock brakes " A/C . . . . . . . . . . . . . . . . . . . . . . . . . . .airconditioning " AST/ASC+T . . . . . ... . . . . . . . . . . . al¡ season traction " CONV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . convertible " DME . . . . . . . . . . . . . . . . . . . . digital motor electronics " ECM . . . . . . . . . . . . . . . . . . electronic control module " EWS/EWS II . . . . . . . . . . . coded driveaway protection " SRS . . . . . . . . . supplemental restraint system-airbag " TCM . . . . . . . . . . . . . . . . transmission control module " ZKE (94-98 models) . . . . . . . . central body electronics " ZVM (92-93 models). . . . . . . . . . . . . . . central locking

ELECTRICAL TROUBLESHOOTING Four things are required for current to flow in any electrical circuit: a voltage source, wires or connections to transport the voltage, a load or device that uses the electricity, and a connection to ground . Most problems can be found using a digital multimeter (volt/ohm/amp meter) to check for voltage supply, for breaks in the wiring (infinite resistance/no continuity), orfor a path to ground that completes the circuit. Electric current is logical in its flow, always moving from the voltage source toward ground . Electrical faults can usually be located through a process of elimination . When troubleshooting a complex circuit, separate the circuit into smaller parts. The general tests outlined below may be helpful in finding electrical problems . The information is most helpful when used with the wiring diagrams . Be sure to analyze the problem. Use the wiring diagrams to determine the most likely cause . Get an understanding of how the circuit works by following the circuit from ground back to the power source . When making test connections at connectors and components, use care to avoid spreading or damaging the connectors or terminals. Some tests may require jumper wires to bypass components or connections in the wiring harness. When connecting jumper wires, use blade connectors at the wire ends that match the size of the terminal being tested . The small interna¡ contacts are easily spread apart, and this can cause intermittent or faultyconnections that can lead to more problems.

Alternator warning light and field energizing circuit

ELECTRICAL TROUBLESHOOTING

600-4

ELECTRICAL SYSTEM-GENERAL

Voltage and Voltage Drops

from Battery

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 by problems ranging from dim 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 connections . A voltage drop test is a good test to make if current is flowing through the circuit, but the 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 should not exceed 0.5 volts.

NOTE-

" A voltage drop test is generally more accurate than a simple resistance check because the resistances involved are often too small to measure with most ohmmeters . For example, a resistance as small as 0.02 ohms would results in a 3 volt drop in a typical 150 amp starter circuit. (150 amps x 0.02 ohms =3 volts) . " Keep in mind that voltage with the key on and voltage with the engine running are not the same. With the ignition on and the engine off (battery voltage), voltage should be approximately 12.6 volts. With the engine running (charging voltage), voltage should be approximately 14.0 volts. Measure voltage at the battery with the ignition on and then with the engine running to get exact measurements.

Voltage, measuring 1 . Connect digital multimeter negative lead to a reliable ground point on car.

NOTE-

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

2. Connect digital multimeter positive lead to point in circuit you wish to measure. See Fig. 1 . If a reading is obtained, current is flowing through circuit.

NOTE-

The voltage reading should not deviate more than 1 volt from the voltage at the battery. If the voltage drop is more than this, check for a corroded connector or cose ground wire.

ELECTRICAL TROLIBLESHOOTING

Switch

r_l

No voltage

-1

Load

J 0013238

Fig . 1 . Digital multimeter being used to test voltage .

Voltage drop, testing Voltage drop can only be checked when current is running through the circuit, such as by operating the starter motor or turning on the headlights . A digital multimeter should be used lo ensure accurate readings . 1 . Connect digital multimeter positive lead to positive (+) batteryterminal or a positive power supply close lo bat tery source . 2. Connect digital multimeter negative lead to other end of cable or switch being tested . See Fig. 2. 3. With power on and circuit working, meter shows voltage drop (difference between two points). This value should not exceed 1 volt.

NOTE-

The maximum voltage drop in an automotive circuit, as recommended by the Society of Automotive Engineers (SAE), is as follows : 0 volts for small vire connections; 0.1 Volts for high current connections; 0.2 volts for high current cables ; and 0 .3 volts for switch or solenoid contacts. On longer wires or cables, the drop may be slightly higher. In any case, a voltage drop of more than 1 .0 volt usually indicates a problem.

ELECTRICAL SYSTEM - GENERAL

600- 5

from Battery

Brake pedal in rest position Q DC

Brake light switch

Brake pedal depressed 0013239

Fig. 2. Digital multimeter being used to check for voltage drop across a switch .

Brake light switch

Continuity, checking The continuity test can be used 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 can be easily checked for faults using an ohmmeter. An open circuit or a circuit with high resistance will not allow current to flow. A círcuit with little or no resistance allows current to flow easily . CAUTIONUse only a high quality digital ohmmeter having high input impedance when checking electronic componente. The internal power source used in most analog (swing-need1e) meters can damage solid state components.

When checking continuity, the ignition should be off. On circuits that are powered at all times, the battery should be disconnected. Using the appropriate wiring diagram, a circuit can be easily tested for faulty connections, wires, switches, relays, and engine sensors by checking for continuity . For a continuity check on a brake light switch, see Fig. 3..

Fig. 3. Brake light switch being tested forcontinuity. With brake pedal in rest position (switch open) there is no continuity (infinite ohms). With pedal depressed (switch closed)there is continuity (zero ohms). Shorts to ground can be located with a digital multimeter . Short circuits are often difficult to locate and may vary in nature . Short circuits can be found using a logical approach based on the current path . CAUTION " On circuits protected with high rating fuses (25 amp and greater), the wires or circuit components may be damaged before the fuse blows. Always check for damage before replacing fuses of this rating. " When replacing blown fuses, use only fuses having the correct rating. Always confirm the correct fuse rating printed on the fuselrelay panel cover

Short Circuits A short circuit is exactly what the narre implies. The circuit takes a shorter path than 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 part of the car 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 TROUBLESHOOTING

00-6

ELECTRICAL SYSTEM-GENERAL Short circuit, testing with voltmeter

Short circuit, testing with ohmmeter 1 . Remove blown fuse from circuit and disconnect cables from battery. 2. Disconnect harness connector from circuit's load or consumer. 3. Using an ohmmeter, connect one test lead to load side of fuse terminal (terminal leading to circuit) and the other test lead to ground . See Fig . 4.

2. Disconnect harness connector from circuifs load or consumer.

NOTEMost fuses power more than one consumer. Be sure aff consumers are disconnectedwhen checking fora short circuit. 3. Using a voltmeter, connect test leads across fuse terminals . See Fig. 5. Make sure power is present ín circuit. lf necessary turn key on .

from Battery

n vu .u

1 . Remove blown fuse from circuit.

from Battery

Shotrouit to earthth Switch

I ~2.U

Load disconnected Load 0013241

Fuse box Short-circuit to earth

Load disconnected

Fig. 4. Digital multimeter being used as an ohmmeter to find short circuit. 4. lf there is continuity to ground, there is a short to ground .

0013240

5. If there is no continuity, work from wire harness hearest to fuse/relay panel and move or wiggle wires while observing meter. Continue to move down harness until meter displays a reading. This is the location of short to ground .

Fig. 5. Digital multimeter being used as a voltmeter to find short cir cuit .

Visually inspect the wire harness at this point for any faults . If no faults are visible, carefully slice open the harness cover or the wire insulation for further inspection . Repair any faults found.

5. lf voltage is not present, work from wire harness nearest to fuse/relay panel and move or wiggle wires while observing meter. Continue to move down harness until meter displays a reading. This is the location of short to ground .

4. lf voltage is present at voltmeter, there is a short to ground .

6. Visually inspect wire harness at this point for any faults . lf no faults are visible, carefully slice open harness cover or wire insulation for further inspection . Repair any faults found.

ELECTRICAL TROUBLESHOOTING

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL COMPONENT LOCATIONS

610-1

610 Electrical Component Locations GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610-1

FOSE POSITION TABLES . . . . . . . . . . . . . 610-19

FUSE AND RELAY POSITIONS . . . . . . . . . 610-1 Fuse Positions . . . . . . . . . . . . . . . . . . . . . . . . 610-1 Relay Positions . . . . . . . . . . . . . . . . . . . . . . . . 610-2 Auxiliary Relay Panel . . . . . . . . . . . . . . . . . . . 610-2 Splice Panel, Left . . . . . . . . . . . . . . . . . . . . . . 610-2 Splice Panel, Right . . . . . . . . . . . . . . . . . . . . . 610-3

TABLES a. E36 Component Locations . . . . . . . . . . . . . . . . . . 610-10 b. 1992 E36 Fuse Positions . . . . . . . . . . . . . . . . . . . 610-20 c. 1993 E36 Fuse Positions . . . . . . . . . . . . . . . . . . . 610-22 d. 1994 E36 Fuse Positions . . . . . . . . . . . . . . . . . . . 610-24 e. 1995 E36 Fuse Positions . . . . . . . . . . . . . . . . . . . 610-26 f. 1996 E36 Fuse Positions . . . . . . . . . . . . . . . . . . . 610-28 g. 1997-1998 E36 Fuse Positions . . . . . . . . . . . . . . . 610-30

COMPONENT LOCATIONS . . . . . . . . . . . . .610-3 Component Location Table . . . . . . . . . . . . . . . 610-9

GENERAL

FUSE AND RELAY POSITIONS

This repair group covers fuse, relay, and control module location information . Electrical equipment and accessories installed varies depending on model and model year . Always confirm that the proper electrical component has been identified by using the electrical wiring diagrams .

The front power distribution box, an auxiliary relay panel, and two auxiliary splice panels contain most of the fuses and relays in E36 vehicles . Refer to the component location later in this section, as well as the tables at the end of this repair group for electrical component location .

WARNING On cars equipped with airbags, special precautions apply to any electrical system testing or repair. Airbag units are explosive devices and must be handled with extreme care. Before starting any work on an airbag equipped car, refer to the wamings and cautions in 721 Airbag System (SRS). CAUTION " Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii. " Relay and fuse positions are subject to change and may vary from car to car. If questions arise, an authorized BMW dealer is the best source for the most accurate and up-to-date information. " A good way to verify a relay position is to compare the wiring colors at the relay socket to the colors indicated on the wiring diagrams located at the rear of this manual. " Always switch the ignition off and disconnect the negative (-) battery cable before removing any electrical components . " Connect and disconnect ignition system wires, multiple connectors, and ignition test equipment leads only while the ignition is switched off. " Only use a digital multimeter for electrical tests.

Fuse Positions CAUTION " Replace fuses with those of the same rating . Installing a fuse with higher rating can lead to circuit failure and may also start a fire . " Relay/fuse positions vary by model and equipment.

Fuses number 1 through 46 are mounted in the front power distribution box. See Fig. 1 . Fuses 1-20

Fuses 31-46

~Illlllllllll °-Ilmmlmomlmoi

(a 1:1 E El ~

~O!7

L~~n Fuses 21-30

4~ i

0013034

Fig. 1 . Fuse positions 1-46 in front power distribution box. FUSE AND RELAY POSITIONS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

610-2

ELECTRICAL COMPONENT LOCATIONS

Fuses number 47 and 50 are mounted on the left side splice panel. Refer lo Fig. 5. Fuse 48 is mounted on the auxiliary relay panel. Refer to Fig. 3.

¡ni

Fuse 49 is mounted in the right side of the luggagecompartment behind the trim cover.

Relay Positions Mounted in the left-hand rear comer of the engine compartment, the power distribution box contains 46 (uses and 15 relay positions. See Fig. 2.

Fuses 31-46

1 . Comfort relay (where applicable) 2. Crash control module 3. Park ventilation relay

Fuses1-20

-Era&QTM M ~ 13

Fuses 21-30 -1 . Fuel pump relay 2. System (main) relay 3. Oxygen sensor heater relay 4. Horn relay 5. Taillight/foglight relay 6. Low beam relay 7. High beam relay 8. Emergency flasher relay

EL1 ] mmmmmmmmmm

Fuse 48)

0013035

4. Not used 5. Not used 6. EWS II transmitter/receiver module (from Jan. 1995)

Fig. 3. Auxiliary relay panel under left side of dash .

0013034)

Heater/A/C Blower relay Rear defogger relay ABS system relay ABS pump relay High speed radiator fan re]ay 14 . A/C compressor relay 15 . Low speed radiator fan re¡ay 9. 10 . 11 . 12 . 13 .

Fig. 2. E36 front power distribution box.

Auxiliary Relay Panel The auxiliary relay panel contains five relay positions. In later modeis an additional fuse holder (Fuse 48) and the EWS II (anti-theft) transmitter/receiver module are located on this panel. See Fig. 3. The panel is located next to the steering column under the driver's side dashboard. To access this panel, remove the pwer dash panel on driver's side . See 513 Interior Trim . Then remove the driver's side knee bolster. Lower the relay panel by gently releasing the plastic retainers. See Fig. 4. During installation, be sure the retainer tabs are engaged in the relay panel.

FUSE AND RELAY POSITIONS

0013164

Fig. 4. Auxiliary relay panel under left side of dashboard (arrow).

Splice Panel, Left The left splice panel contains four relay positions and an additional fuse holder (Fuses 47 and 50). To access the left side electrical splice panel, remove the left side dash panel and knee bolster, as described earlier. The panel is located above and lo the left of the clutch pedal. See Fig. 5 .

ELECTRICAL COMPONENT LOCATIONS

610-3

COMPONENT LOCATIONS On the following pages are illustrations and photos showing the location of major electrical components in E36 vehicles . NOTE- Every component is not installed in every car. " Due to changes in production, component locations may vary from what is illustrated. Consult your BMW dealer for the latest information . " The gear-position/neutral safety switch ís also sometimes referred to as the automatic transmission range switch. " The EWS 11 system is also sometimes referred to as the Driveaway Protection System or the electronic immobilization system .

1 . Unloader relay 2 . Wiper relay 3 . Wiper motor relay

0013091

" All-Season Traction (AST) is also sometimes referred to as ASC or ASC+T.

4 . Starter immobilization relay (1994 only) F47 & F50 Fuses 47 and 50

Fig. 5. Splice panel under left side of dash .

Splice Panel, Right The right splice panel contains three relay positions . It is located under the right side of the dashboard . To access the panel, remove the glove compartment as described in 513 Interior Trim . See Fig . 6 .

ir1!1,111lí~lll. '

Fig . 6 . Splice panel under right side of dash (arrow) . Glove compartment and right side vents shown removed .

COMPONENT LOCATIONS

610-4

ELECTRICAL COMPONENT LOCATIONS

ABS hydraulic control unit

Main engine harness connector

Power distribution box

--J L

Windshield washertank & pump Fig. 7.

E36 engine compartment layout . M42 engine compartment shown .

RSP 'I

1. 2. 3. 4.

-,x

0013204

Fig . 8 . Control modules under right side of dash . Glove compartment has been removed . For module identification, see Fig . 9.

SRS (Airbag) control module (through 1993) ABS/ASC+T control module (as applicable) Central locking module (through 1993) Anti-theft alarm module or ZKE IV control module (from 1994) 5 . Rear window blower relay (convertible models) 6 . Horn relay 7 . Wiper/washer module 8 . Rear power window relay (four-door models) 9 . Luggage compartment lid lock relay (convertible) 10 . Cruise control module EWS II control module (from Jan . 1995) RSP : Right splice panel

0013215

Fig. 9. Identification of control modules under right side of dash . Module utilízation varies by year and model COMPONENT LOCATIONS

ELECTRICAL COMPONENT LOCATIONS

610-5

0012421

Fig . 12. M44 engine intake air temperature (¡Al) sensor in air filter housing

1 . Heater valves 2 . ABS pedal travel sensor 3 . ABS pump

4. Main engine harness connector 5 . Power distribution box

Fig . 10 . Left rear of engine compartment.

0013202

301180

Fig. 13 . M50/S50US engine intake air temperature (IAT) sensor (1) and throttle position sensor (2) .

0013226

Fig . 11 . M42 engine idie speed control valve (arrow) beneath intake manifold

0012724

Fig . 14. M52/S52US engine intake air temperature (IAT) sensor in bottom of intake manifold (throttle housing shown removed) . COMPONENT LOCATIONS

610-6

ELECTRICAL COMPONENT LOCATIONS

811004

Fig . 17 . Six-cylinder ignition coil in top of cylinder head (M52 engine) .

Fig. 15 . M44 engine harness connectors at air intake

0012427

Fig . 18 . Cooling fan dual switch in radiator (arrow) . 0011644

Fig . 16. A/C recharging ports (arrows), right rear of engine compartment

COMPONENT LOCATIONS

0013203

ELECTRICAL COMPONENT LOCATIONS

00119s4

Fig . 19 . M44 engine coolant temperature (ECT) sensor (arrow) .

610-7

0013131

Fig . 22 . Headlight ground at left front of engine compartment (arrow).

0012704

Fig . 20 . M52 engine coolant temperature (ECT) sensor (A) is located beneath top engine cover (B) and crankcase vent hose (C) .

uvijijo Fig . 23 . Main ground at right strut tower (A) . B is negative jumper connection .

uu12700

Fig . 21 . M52 throttle position sensor (A), idle speed control valve (B), and secondary air pump (C) .

COMPONENT LOCA TIONS

610-$

ELECTRICAL COMPONENT LOCATIONS

0013108

Fig . 26 . Passenger side airbag connector (arrow) behind glove compartment .

0011751

Fig . 24. Brake pedal switches .

Fig . 27 . Antenna diversity module (arrow) in left C-pillar.

0013010

Fig. 25. Driver side airbag connector (arrow) .

Fig . 28. Right side of fuel tank under rear seat cushion .

0013142

COMPONENT LOCATIONS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL COMPONENT LOCATIONS

610-9

0012117

Fig . 31 . ASS wheel speed sensor (arrow) in front steering arm .

Fig . 29. Transmission gear-position/neutral safety switch under center console . Squeeze connector tabs (arrows) to disengage harness connector

Component Location Table Table a is a cross-referenced listing of electrical components in E36 vehicles beginning on page 10 . In addition to location descriptions, where possible there is a reference to a figure showing the component . NOTE- Every component is not installed in every car. " Due to changes in production, component locations may vary. Consult your BMW dealer for the latest information . " The figure numbers are all within this section . Many other electrical components are illustrated throughout this book. Consult the main index " The gear-position/neutral safety switch is aleo sometimes referred to as the automatic transmission range switch .

6263

Fig . 30 . Back-up light switch (arrow) on transmission . (Switch may be found on right or left side of transmission, depending on application.)

" The EWS 11 system is also sometimes referred to as the Driveaway Protection System or the electronic immobilization system. " All-Season Traction (AST) is also sometímes referred to as ASC or ASC+T.

COMPONENT LOCATIONS

610-10

ELECTRICAL COMPONENT LOCATIONS Table a. E36 Component Locations

Component

Model Year

Location

Refer to

ABS Hydraulic Control Unit

1992-1998

Left rear engine compartment under master cylinder

Fig . 7 . Fig . 10 .

ABS Hydraulic Control Unit Relay

1992-1998

Power distribution box

Fig . 2 .

ABS Pedal Travel Sensor

1992-1998

On brake booster beside master cylinder

Fig . 10 .

ABS Relay

1992-1998

Power distribution box

Fig . 2 .

ABS/AS T (Traction) Control Module

1992-1998

Behind glove compartment

Fig . 8 . Fig . 9 .

ABS Speed Sensor, Left Front Wheel

1992-1998

Left front steering arm

Fig . 31 .

ABS Speed Sensor, Left Rear Wheel

1992-1998

Left rear trailing arm

ABS Speed Sensor, Right Front Wheel

11992-1998

ABS Speed Sensor, Right Rear Wheel

1 1992-1998

Right front steering arm I Left rear trailing arm

A/C Compressor

1992-1998

( Right lower front of engine

A/C Compressor Control Relay

1992-1998

Power distribution box

A/C Control Module

1992-1998

Behind center console

A/C Evaporator Temperature Sensor

1992-1998

Left side of heater box

A/C Pressure Switch

1992-1998

Right front of engine compartment

A/C Program Switch

1992-1998

Center of dash below radio

A/C Recharging Ports

1992-1998

Right rear engine compartment

Fig . 16.

Air Flow Sensor

1992-1998

Between throttle housing & filter housing

Fig . 7 .

Airbag Contact Slip Ring

1992-1998

Rear of steering wheel

Airbag, Driver

1992-1998

In center of steering wheel

Fig. 25 .

Airbag, Passenger

1994-1998

Right front of dash above glove compartment

Fig. 26 .

Airbag, Side-Impact

1997-1998

Behind right/left front door panel

Airbag Control Module (Basic)

1992-1993

Behind glove compartment

Airbag Control Module (ZAE)

1994-1998

On center tunnel under rear seat cushion

Airbag Crash Sensor, Airbag

1992-1993

On righUleft front strut tower

Airbag Crash Sensor, Right/Left Side Impact

1997-1998

Right/left door si¡¡ behind front seat

Alternator (Generator)

1992-1998

Left lowerfront of engine

Amplifier Hi-fi

1992-1998

Left front side of luggage compartment

Antenna Amplifier AM/FM

1992-1998

In upper left side C-pillar

Fig . 2 .

Fig . 8 . Fig . 9 .

Fig. 27. Continued

COMPONENT LOCA TIONS

ELECTRICAL COMPONENT LOCATIONS

610-11

Table a. E36 Component Locations

Component

Model Year

Location

Refer to

Anti-theft Control Module

1992-1998

Behind glove compartment

Fig . 8 . Fig . 9 .

1 1992-1998

1 Right rear engine compartment

Anti-theft Horn Anti-slip (Traction) Control Module (AST/ASC+T)

1994-1998

Power distribution box

Anti-slip (Traction) Control Switch

1994-1998

In center console

Automatic Climate (A/C) Control Module

1992-1998

Behind center console

Automatic Transmission Range Switch (Gear Position/Neutral Safety Switch)

1992-1998

Auxiliary Cooling Fan Dual Switch

1992-1998

Right side radiator

Auxiliary Cooling Fan Motor

1992-1998

Behind front grill

Auxiliary Fuse Box (Left Splice Panel)

1992-1998

I Behind left front footwell kick-panel

~ Next to gear shift lever in center console

Auxiliary Relay Panel

1992-1998

Left side of dash under steering column

Auxiliary Fuse Box In Trunk

1997-1998

Right side of trunk behind trim panel

AuADSry

Throttle Position Motor

Fig . 8 . Fig . 9.

Fig . 29 .

Fig. 18 .

Fig. 5 . Fig. 4 .

Front of engine compartment

11994-1998

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 (ZKE IV)

1994-1998

Behind glove compartment

Fig . 8 . Fig . 9 .

Brake Fluid Level Sensor

1992-1998

Top of brake fluid reservoir at master cylinder

Fig . 15 . Fig . 24 .

Brake Light Switch

1992-1998

On brake pedal support bracket

Brake Pad Sensor, Left Front

1992-1998

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 Identification)

1992-1998

Front of engine

Carbon Canister Valve (TLEV)

1997-1998

Central Locking Module (ZVM)

11992-1993

Check Control Module (if applicable)

1992 - 1998

In spare wheel well in trunk

1 Behind glove compartment 1

Fig . 7 .

I Fig . 8 . Fig . 9 .

Below left side of dash

Child Protection Window Control (console)

1992-1998

Center console

Chime Module

1992-1998

Below left side of dash in left dash trim panel

Clock (Multi-Function)

1993-1998

Center console

Clutch Pedal Switch

1992-1998

On clutch pedal support bracket Continued

COMPONENT LOCATIONS

610-12

ELECTRICAL COMPONENT LOCATIONS Table a. E36 Component Locations Refer to

Component

Model Year

Location

Combination (Stalk) Switch

1993-1998

Left side steering column (turn signals/high-low bean switch)

Convertible Top Actuating Switch

1994-1998

Center console

Convertible Top Control Module

1994-1998

In lower left C-pillar behind trim panel

Convertible Top End Position Switch

1994-1998

In convertible top linkage

Convertible Top Motor

1994-1998

In left side of trunk behind trim panel

Convertible Top Position Microswitch

1994-1998

In convertible top linkage

Convertible Top Storage Lid Lock Motor

1994-1998

In convertible top compartment left side

Convertible Top Storage Lid Microswitch

1994-1998

In right side convertible top storage lid latch

Convertible Top Storage Lid Motor

1994-1998

In left side of trunk behind trim panel

Coolant Leve¡ Sensor (if applicable)

1992-1998

Bolted on radiator, left side

Coolant Temperature Sensor

1992-1998

Left front of engine/cylinder head

Fig . 19 . Fig . 20 .

Cooling Fan Dual Switch

1992-1998

Right side radiator

Fig . 18 .

Cooling Fan Motor

1992-1998

Behind front grill

Crankshaft Position/RPM Sensor

1992-1995

At front crankshaft pulley

Crankshaft Position/RPM Sensor

1996-1998

Left rear of crankcase

Crash Sensor, Airbag

1992-1993

On right/left front strut tower

Crash Control Module

1992

Auxiliary relay panel

Crash Control Module

1993-1998

Driver's side footwell

Crash Sensor, Right/Left Side Impact Airbag

1997-1998

Right/left door sill behind front seat

Cruise Control Actuator

1992-1998

Left front of engine compartment

Fig . 7 .

Cruise Control Module

1992-1998

Behind glove compartment

Fig . 8 . Fig . 9 .

Data Link Connector

1992-1998

Right side of engine

Fig . 7 .

Digital Motor Electronics (DME) Control Module

1992-1998

Right rear engine compartment, behind bulkhead panel

Fig . 7 .

Door Lock Heater

1993-1994

Left front door handle

Door Handle Switch

1994-1998

left front door

Drive-away Protection (EWS II) Module

1/1995 - 1998

Behind glove compartment

Fig. 8 . Fig. 9 .

Dual Coolant Temperature Sensor

1997-1998

Below intake manifold

Fig. 19 . Fig. 20 .

Electronic Immobilizer Control Module (EWS II)

( 1/1995-1998 ~ Behind glove compartment

Fig. 8 . Fig. 9 .

Continued

COMPONENT LOCATIONS

ELECTRICAL COMPONENT LOCATIONS

610-13

Table a . E36 Component Locations Component

Model Year

Location

Refer to

Engine Compartment Light Switch

1993-1996

Over right headlight assembly

Fig . 7 .

Engine Control Module (ECM)

1992-1998

Right rear engine compartment, behind bulkhead panel

Fig . 7 .

Engine Control Module (System) Relay

1992-1998

Engine Coolant Leve¡ Sensor

1 1992-1998

Engine Coolant Temperature Sensor

1992-1998

Evaporative Emission Valve

1992-1998

Left side strut Power area

Evaporator Temperature Sensor

1992-1998

Left side of heater box

EWS II Control Module

1/1995 - 1998

Behind glove compartment

EWS II Ring Antenna

I Power distribution box

1 Left front of engine compartment, radiator coolant reservoir

I Left front of engine under intake manifold

1/1995 - 1998

Right side of steering column in auxiliary relay panel

Exhaust Gas Flap Valve

1996-1998

Left rear muffler area

Flasher Relay

1992-1998

Power distribution box

Foglight Relay

1 1992-1998

1 Power distribution box

Fresh Air Flap Actuator

1 1992

1 Right side of heater box

Fresh Air Flap Actuator

1 1993-1995

1 Below right side heater box

Fuel Injectors

I Fig . 19 . Fig . 20 .

Fig . 8 . Fig . 9 .

1 1/1995 - 1998 1 At ignition cylinder

EWS II Transmitter Module

Fresh Air Flap Actuator

Fig . 2 .

1 1996-1998 1992 - 1998

Fig . 3 .

Fig . 2 . 1

Fig . 2 .

Below left side heater box Top left side of engine

Fuel Leve¡ Sensor, Left

1 1992-1998

/ Under left side of rear seat in fuel tank

Fuel Leve¡ Sensor, Right

1 1992-1998

1 Under right side of rear seat in fuel tank

Fig. 28.

Fuel Pump

1 1992-1998

1 Under right side of rear seat in fuel tank

Fig. 28 .

Fuel Pump Relay

1 1992-1998

1 Power distribution box

Fig . 2 .

1994 - 1996

Power distribution box

Fig . 2 . Fig . 7 Fig . 10 .

Fuel Pump/Start Identification Relay Fuel Tank Pressure Sensor

1 1997-1998

1 Right rear wheel well behind trim liner

Fuse and Relay x (Power Distribution Box

11992-1998

I Left side of engine compartment

Gas Filler Lock Motor

1992-1998

Right side of luggage compartment

Gear Position/Neutral Safety Switch (Automatic Transmission Range Switch)

1992-1998

Next to gear shift lever in center console

Glove Compartment Lock Motor

1994-1998

Behind glove compartment

G 100

1995-1998

Front of left front fender (headlights)

G 101

1992-1998

Front of right front fender

Fig . 29 .

Grounds Fig . 22 .

Continued

COMPONENT LOCATIONS

610-14

ELECTRICAL COMPONENT LOCATIONS Table a. E36 Component Locations

Component

Model Year

Location

G 102

1992-1998

Left front strut tower

G 103

1992-1998

Right front strut tower

G 110

1992-1998

Left front of engine

G 111

1992-1998

Near battery

G 117

1992-1998

Right rear of engine

G 119

1992- 1998

Right front of engine

G 123

1992-1998

Right side of safety wall

G 200

1992-1998

Left kick panel

G 201

1992-1998

Right side of I/P

G 202

1992-1998

Left side of I/P

G 203

1992-1998

Right kick panel

G 230

1992-1998

Right kick panel

G 301

1992-1998

Below right front seat

G 302

1992-1998

Below center console

G 303

1992-1998

Below right rear seat

G 310

1992-1998

Behind right rear seat

G 312

1992-1998

Behind left rear seat

G 313

1992-1998

Right side of rear shelf

G 314

1992-1998

Left side of rear shelf

G 400

1992-1998

Left front side of trunk

G 404

1992-1998

Left rear side of trunk

Camshaft Position Sensor

1992-1998

Front of engine

Hard Top, Connector 1

1994-1998

In convertible top compartment left side

Hard Top, Connector II

1994-1998

In convertible top compartment left side

Hazard Flasher Relay

1992-1998

Power distribution box

Headlight High Beam Relay

1998

Left hand side of dash behind instrument cluster

Headlight High Beam Relay

1992-1997

Power distribution box

Headlight Low Beam Relay

1992-1998

Power distribution box

Heat Exchanger Temperature Sensors (left and right)

1993-1998

Center console

Heater Blower Motor

1992-1998

Behind fresh air cowl

Heater Blower Motor Relay

1992-1998

Power distribution box

Heat Rear Recirculation Flap Actuator

1997-1998

Right side of heater box

Refer to

Fig . 7.

Fig . 2 .

Fig. 2 .

Continued

COMPONENTLOCATIONS

ELECTRICAL COMPONENT LOCATIONS

610-15

Table a. E36 Component Locations

Component

Model Year

Location

Heater Recirculation Flap Actuator

1992-1998

Below left dash right side of steering column

Heater Blower Motor Resistor Pack

1992-1998

Behind center of dashboard

Heater Regulator Flap Actuator

1997-1998

Right side of heater box

Heater Valve Assembly

1992-1998

Left rear engine compartment

HeatingNentilation Relay Box

1992-1993

Below left side of dash

HeatingNentilation Relay

1994-1998

Left front footwell

High Speed Cooling Fan Relay

1992-1998

Power distribution box

Homs, Right/Left

1993-1998

Front of engine compartment

Horn Relay

1992-1998

Power distribution box

Fig . 2 .

Horn Relay (Alpine) Board Computer/Anti-Theft

1994-1998

Behind glove compartment

Fig . 8 . Fig . 9 .

Idle Speed Control Valve

1992-1995

Top rear of engine behind intake manifold (M42 engine)

Fig . 11 .

Idle Speed Control Valve

1992-1995

Top left side of engine (M50 engine)

Idle Speed Control Valve

1993-1996

Below intake manifold (M50/S50US engine)

Idle Speed Control Valve

1996-1998

On throttle housing (M44 engine)

Idle Speed Control Valve

1997-1998

Left front of engine below intake manifold (M52/S52US engine)

Ignition Coils

1992-1998

Right of engine under plastic cover (four-cylinder)

Fig . 7 .

Ignition Cofs

1992-1998

Top of engine under cover (six-cylinder)

Fig . 17 .

Ignition Switch

1992-1998

Right síde of steering column

Intake Air Resonance Changeover Valve (DISA)

1992-1998

Left rear of engine compartment

Intake Air Temperature Sensor

1992-1995

In mass air flow sensor (M42 engine)

Intake Air Temperature Sensor

1996-1998

In top of air filter housing (M44 engine)

Intake Air Temperature Sensor

1992-1998

I Left síde of engine in intake manifold (six-cylinder)

Fig . 2 .

Fig . 15 .

Fig . 12 .

I Fig . 13 . Fig . .

1 Left footwell

Kick-Down Switch (A/T)

1 1992-1998

Knock Sensors

Left Front Power Window Motor

11992-1998

Left Front Window Monitoring Switch

1997-1998

Left front door trim panel

Left Front Window Retraction Switch

1992 - 1993

Left front door handle lock assembly

Left Splice Panel

1992-1998

Under left side of dash at kick-panel

1992-1998

Refer to

Left side of engine block

/ Left front door

Fig . 5 .

Main Fuse and Relay Box (Power Distribution Box)

1 1992-1998

I Left side of engine compartment

Fig . 2.

Mass Air Flow Sensor

1 1992-1998

I Left side of engine, intake air duct

Fig . 7 . Fig . 15 .

Mixing Actuators

1 1992-1998

1 Heater box Continued

COMPONENT LOCATIONS

610-16

ELECTRICAL COMPONENT LOCATIONS Table a. E36 Component Locations

Refer to

Component

Model Year

Location

Mixing Switch

1992-1994

Center console

Multi-Function Clock

1992-1998

Center console

Multi-information Display (MDI)

1992-1998

Center console

Normal Speed Cooling Fan Relay

1992-1998

Power distribution box

Fig . 2 .

Neutral Safety Switch (Automatic Transmission Range Switch)

1992-1998

Next to gear shift lever in center console

Fig . 29 .

Oil Pressure Switch

1992-1998

Left front of engine below intake manifold at oil filter housing

On-Board Computer

1992-1998

Center console

On-Board Computer Horn Relay

1992-1998

Behind glove compartment

On-Board Computer Temperature Sensor

11992-1998

I Right front of engine compartment

Outside Temperature Sensor

1992-1997

In right front brake cooling duct

Outside Temperature Sensor

1998

Right rear of engine compartment behind fresh air cowl

Oxygen Sensor Heater Relay

1992-1998

Power distribution box

Oxygen Sensor(s)

1992-1998

On exhaust pipe ahead/behind catalytic converter (M42/M44 engine)

Oxygen Sensor (x2)

1992-1995

On exhaust pipe ahead of catalytic converter (M50/S50US engine)

Oxygen Sensors (x4)

1996-1998

On exhaust manifold/exhaust pípe behind catalytic converter (M52/S52US engine)

Parking Brake Switch

1 1992-1998

I On rear of parking brake lever

Power Distribution Box

11992-1998

I Rear left of engine compartment

1992 - 1996

Center console behind radio

Radio Microswitch

Fig . 8 . Fig . 9 .

Fig . 2 .

Fig . 2. Fig . 7. Fig . 10 .

Fig . 2 . Fig . 7 . Fig . 10 .

Right rear luggage compartment

1997-1998

Relay And Fuse Box (Power Distribution Box)

1992-1998

I Left side of engine compartment

Rear Window Blower

1994-1998

Behind rear seat (convertible)

Rear Window Blower Microswitch

1994-1994

At convertible top linkage

Rear Window Blower Microswitch

1995-1998

Behind rear seat (convertible)

Rear Window Blower Relay

11994-1998

Behind glove compartment

Fig . 8. Fig . 9 .

Rear Window Defogger Relay

1992-1998

Power distribution box

Fig . 2 .

Reversing (Back-up) Light Switch

1992-1998

Right or left side top of transmission

Fig . 30.

Splice Panel, Right

1992-1998

Behind glove compartment

Fig . 8 . Fig . 9 .

11994-1998

Behind rear seat (convertible)

Radio Receíver

Rollover Protection Actuator

Continued

COMPONENT LOCATIONS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL COMPONENT LOCATIONS

610-17

Table a . E36 Component Locations Component

Model Year

Location

Rollover Sensor

1994-1998

In lower left C-pillar behind trim panel (Convertible)

Seat Belt Switch

1992-1998

In front seat belt buckle

Seat Cushion Tilt Motor

1992-1998

Under front seat

Seat Heater

1993-1998

Under front seat

Seat Height Motor Front

1992-1998

Under front seat

Seat Movement Motor

1992-1998

Under front seat

Seatback Heater

1993-1998

In upper front seatback

Seatback Recliner Motor

1993-1998

Under front seat

Seat Occupancy Detector

1994-1998

Under right front seat

Secondary Air Pump (4-cyl .)

19971/2 - 1998

Left engine compartment, below power distribution box (M44 engine)

Secondary Air Pump (6-cyl .)

1996-1998

Front of engine compartment (M52/S52US engine)

Secondary Air Pump Relay

1996-1998

Power distribution box

Secondary Air Pump Valve

1996-1998

Right side of engine

Side Impact Air Bag Right/Left

1997-1998

Behind right/left door trim panel

Síde Impact Airbag Crash Sensor, Right/Left

1997-1998

Right/left door si¡¡ behind front seat

Shift Interlock

1992-1998

Center console beside shift selector

Slip Control Module (ABS/AST)

1992-1998

Behind glove compartment

Fig . 8 . Fig . 9 .

Splice Panel, Left Side

1992-1998

Behind footwell speaker grill

Fig . 5 .

Splice Panel, Right Side

1992-1998

Behind glove compartment

Fig . 6 .

Starter

1992-1998

Left rear of engine

Starter Immobilization Relay

1994-1998

In left splice panel behind footwell speaker grill

Starter Relay

1992-1993

Below left side of dash

Starter Relay

1994-1998

Behind left footwell speaker grill

Sunroof Control Assembly

1992-1998

In roof center panel

Supplemental Restraint System (Airbag) Control Module

11992-1993

I Behind glove compartment

Supplemental Restraint System (Airbag ZAE) Control Module

1994-1998

1 Under center of rear seat

Switch, Power Window

1 1992-1998

1 Center console

Telephone Eject Box

1 1994-1996

1 Center console

Telephone Transceiver

1992-1992

In luggage compartment

Throttle Flap Heater

1994-1996

Left side of engine

Throttle Position Sensor

1992-1998

I Left side of engine in throttle housing

Refer to

Fig . 2 .

Fig . 8 . Fig . 9 .

Fig . 7. Fig . 15 . Fig . 21 . Continued

COMPONENT LOCATIONS

610-18

ELECTRICAL COMPONENT LOCATIONS Table a . E36 Component Locations

Component

Model Year

Location

Refer to

Transmission Control Module

1992-1998

Right rear engine compartment behínd panel

Fig . 7 .

Transmission Range Switch (Gear Position/Neutra l Safety Switch)

1992-1998

Next to gear shift lever in center console

Fig . 29 .

Transmission Valve Unít

1992-1993

In transmission oil pan

Transmission Valve Unit

1994-1998

On left side of transmission

Trunk Lid Microswitch

1994-1998

In trunk lid

Trunk Lid Relay

1994-1998

Behind glove compartment (convertible)

Trunk Light Switch

1992-1998

Left underside of trunk lid

Trunk Lock Motor

1992-1998

Rear of luggage compartment

Unloader Relay

1992-1998

In left splice panel behind footwell speaker grille

Variable Camshaft Control Module (VANOS)

1994-1996

Variable Camshaft Control (VANOS)

1993-1998

Front of cylinder head

Veh¡cle Speed Sensor

1992-1998

On final drive

Volume Air Flow Sensor (M42 Engine)

1992-1995

Left side of engine compartment

Washer Fluid Leve¡ Sensor

1992-1998

Right front of engine compartment

Washer Pump

1992-1998

Right side of engine compartment on windshield washer reservoir

Wiper Motor

1992-1998

Rear engine compartment

Wiper Motor Relay

1992-1998

In left splice panel behind footwell speaker grill

Wiper Relay

1992-1998

Wiper/Washer Module

1992-1993 (early)

Left side of footwell under foot rest

Wiper/Washer Module

1993 (late)1998

Behind glove compartment

ZAE Airbag Control Module ZKE IV Control Module

COMPONENT LOCATIONS

1 1994-1998 1994-1998

Fig . 8 . Fig . 9 .

Fig . 5 .

I Rear right side of engine compartment

( Behind glove compartment

Fig . 7.

Fig . 7 .

Fig . 5 . I Fig . 8 ./ Fig . 9.

Fig . 8 . Fig . 9 .

1 On center tunnel under rear seat cushion I Behind glove compartment

Fig . 8 . Fig . 9 .

ELECTRICAL COMPONENT LOCATIONS

610-19

FUSE POSITION TABLES Table b through Table g list fuse positions in the power distribution box and, where applicable, in the auxiliary relay panel, the left side splice panel and the luggage compartment. Refer to the beginning of this repair group for locations of these panels .

FUSE POSITION TABLES

ELECTRICAL COMPONENT LOCATIONS

610-20

Table b. 1992 E36 Fuse Positions

Fuses 1-20

Fuses 31-46

o_ ~oomooommmo~

Fuse

(a El 1:1 El

Fuses 21-30

Rating

18 1

15A 1 Fuel pump

19 j

15A 1 Park ventilation (see also fuse 20)

30A ~ Heating and A/C (IHKR E36)(see also fuse 16, 23, 31, 37, 39, 41) Park ventilation (see also fuse 19)

21 1

5A { ABS (see also fuse 10, 27, 38, 46)

Headlights/foglights (see also f use 11, 12, 15, 23, 25, 29, 30) Instrument illumination (see also fuse 25, 33, 37) Park/taillights (see also fuse 33, 37)

Multi-function clock (see also fuse 27, 31, 45, 46) Headlights/foglights (see also fuse 11, 12, 15, 22, 25, 29, 30) Heated seats (see also fuse 4) Heating and A/C (IHKR E36)(see also fuse 16, 20, 31, 37, 39, 41) Instrument cluster (see also fuse 27, 31, 46) On-Board Computer (see also fuse 11, 12, 27, 31, 33, 37, 45, 46) Rear window defogger (see alsofuse 6) Turn signals/hazard lights (see also fuse 34)

0013034

Fuse positions 1-46 in front power distribution box Table b. 1992 E36 Fuse Positions

Fuse 1 Rating 1 Protected Circuit 1 1

30A 1 Power sunroof (see also fuse 13)

2 I

Protected Circult

I Not used

3 1

30A 1 Headlight washer

4 1

15A 1 Heated seats (see also fuse 23)

24 I

10A I Power mirrors

5 1

30A 1 Power seats (see also fuse 40)

6 1

20A 1 Rear window defogger (see also fuse 23)

5A ~ Anti-theft system (Alpine) (see also fuse 43) Central locking (ZVM II) (see also fuse 35, 43)

8 I

15A I Horn

9 (

20A 1 Sound system (see also fuse 44)

15A ~ Back-up lights Electronic transmission control (A4S 310R) (see also fuse 28, 46)

10 1

30A 1 ABS (see also f use 21, 27, 38, 46)

7 .5A

ABS (see also fuse 10, 21, 38, 46) Multi-function clock (see also fuse 23, 31, 45, 46) Instrument cluster (see also fuse 23, 31, 46) On-Board Computer (see also fuse 11, 12, 23, 31, 33, 37, 45, 46)

Cruise control (see also fuse 46) Engine control module (see also fuse 16) Starting system Electronic transmission control (A4S 310R) (see also fuse 26, 46)

7 .5A

Crash control module (see also fuse 11, 12, 25,34) Headlights/foglights (see also fuse 11, 12, 15, 22, 23, 25, 30)

7 .5A

Headlights/foglights (see also fuse 11, 12, 15, 22, 23, 25)

Multi-function clock (see also fuse 23, 27, 45, 46) Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 37, 39, 41) Instrument cluster (see also fuse 23, 27, 46) On-Board Computer (see also f use 11, 12, 23, 27, 33, 37, 45, 46)

7 .5A

Crash control module (see also fuse 12, 25, 29,34) Headlights/foglights (see also fuse 12, 15, 22, 23, 25, 29, 30) On-Board Computer (see also fuse 12, 23, 27, 31, 33, 37, 45, 46) Crash control module (see also fuse 11, 25, 29,34) Headlights/foglights (see also fuse 11, 15, 22, 23, 25, 29, 30) On-Board Computer (see also fuse 11, 23, 27, 31, 33, 37, 45, 46) Power sunroof (see also fuse 1) Power windows (see also f use 14)

14 j

30A 1 Power windows (see also fuse 13)

5A ~ Engine control module (see also fuse 28) Heating and A/C (IHKR E36)(see also fuse 20, 23, 31, 37, 39, 41)

17 I

Headlights/foglights (see also fuse 11, 12, 22, 23, 25, 29, 30)

I Not used

FUSE POSITION TABLES

Crash control module (see also f use 11, 12, 29,34) Headlights/foglights (see also fuse 11, 12, 15, 22, 23, 29, 30) Instrument illumination (see also fuse 22, 33, 37)

ELECTRICAL COMPONENT LOCATIONS Table b. 1992 E36 Fuse Positions Fuse

Rating

Protected Circuit

30A

Glove compartment light/cassette compartmenVashtray light/charging socket/cigar lighter (see also fuse 33, 37, 44)

10A

Cellular telephone (see also fuse 43) Glove compartment light/cassette compartment/ashtray IighUcharging sockeUcigar lighter (see also fuse 32, 37, 44) Interior lights (also see fuse 43) License plate/luggage compartment lights (see also fuse 37) Instrument íllumination (see also fuse 22, 25, 37) On-Board Computer (see also fuse 11, 12, 23, 27, 31, 37, 45, 46) Park/taillights (see also fuse 22, 37)

15A ~ Crash control module (see also fuse 11, 12, 25,29) Turn signals/hazard lights (see also fuse 23)

35 1

25A j Central locking (ZVM II) (see also fuse 7, 43)

36 1

30A 1 Wiper/washer (see also fuse 37, 44, 45)

10A

38 39

7 .5A

40 41

30A

610-21

Table b. 1992 E36 Fuse Positions Fuse

Rating

15A

Protected Circuít ABS (see also fuse 10, 21, 27, 38) Brake lights Multi-function clock (see also fuse 23, 27, 31, 45) Cruise control (see also fuse 28) Electronic transmission control (A4S 310R) (see also f use 26, 28) Instrument cluster (see also fuse 23, 27, 31) On-Board Computer (see also f use 11, 12, 23, 27, 31, 33, 37, 45)

WARNING Fuse designations and locations are subject to change, and may vary from car to car, depending on options. If questions arise, please remember that an authorized BMW dealer is the best source for the most accurate and up-to-date information.

Glove compartment IighUcassette compartmenVashtray light/charging socket/cigar lighter (see also fuse 32, 33, 44) Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 39, 41) Instrument illumination (see also fuse 22, 25, 33) License plate/luggage compartment lights (see also fuse 33) On-Board Computer (see also fuse 11, 12, 23, 27, 31, 33, 45, 46) Park/taillights (see also fuse 22, 33) Wiper/washer (see also fuse 36, 44, 45)

1 ABS (see also fuse 10, 21, 27, 46) Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 37, 41)

30A 1 Power seats (see also fuse 5) 30A ~ Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 37, 39) Radiator auxiliary fan

7 .5A

I Not used

Anti-theft system (Alpine) (see also fuse 7) Cellular telephone (see also fuse 33) Central locking (ZVM II) (see also fuse 7, 35) Interior lights (also see fuse 33)

15A

Glove compartment light/cassette compartmenVashtray light/charging sockeUcigar lighter (see also fuse 32, 33, 37) Sound system (see also fuse 9) Wiper/washer (see also fuse 36, 37, 45)

7 .5A

Multi-function clock (see also fuse 23, 27, 31, 46) On-Board Computer (see also fuse 11, 12, 23, 27, 31, 33, 37, 46) Wiper/washer (see also fuse 36, 37, 44) FOSE POSITION TABLES

ELECTRICAL COMPONENT LOCATIONS

610-22

Table c. 1993 E36 Fuse Positions

Fuses 1-20

Fuses 31-46

fuse

Ylililll

Fuses 21-30

milililil

Rating

21 1

5A 1 ABS (see also fuse 10, 27, 38, 46)

5A ~ Instrument illumination (see also Puse 25, 33, 37) Park/taillights (see also fuse 33, 37)

24 I

10A I Power mirrors

10A ~ Back-up lights Electronic transmission control (A4S 310R) (see also fuse 28, 46)

ABS (see also fuse 10, 21, 38, 46) Multi4unction clock (see also fuse 23, 31, 45, 46) Instrument cluster (see also fuse 23, 31, 46) On-Board Computer (see also fuse 11, 12, 23, 31, 33, 37, 45, 46)

Cruise control (see also fuse 46) Engine control module (see also fuse 16) Starting system Electronic transmission control (A4S 310R) (see also fuse 26, 46)

7.5A

Headlights/foglights (see also fuse 11, 12, 15, 23, 25, 30)

7.5A

Headlights/foglights (see also fuse 11, 12, 15, 23, 25)

30A

Glove compariment light/cassette compartment/ashtray light/charging socket/cigar lighter (see also fuse 33, 37, 44)

0013034

Fuse positions 1-46 in front Power distribution box

Table c. 1993 E36 Fuse Positions

1 Rating

fuse

j Protected Circuit

1 I

30A I Powersunroof

2 I

I Not used

30A 1 Headlight washer

3 4

1 5 1

1 Heated seats (see also fuse 23) 30A 1 Power seats (see also fuse 40)

6 1

20A 1 Rear window defogger (see also fuse 23)

15A

5A 1 Central locking (ZVM) (see also f use 35, 43) 8

15A

9 1

20A 1 Sound system (see also fuse 44)

10 1

30A 1 ABS (see also fuse 21, 27, 38, 46)

7.5A

13 I 14

Anti-theft (Alpine) (see also fuse 43) Horn

Headlights/foglights (see also fuse 12, 15, 23, 25, 29, 30) On-Board Computer (see also fuse 12, 23, 27, 31, 33, 37, 45, 46) Headlights/foglights (see also fuse 11, 15, 23, 25, 29, 30) On-Board Computer (see also fuse 11, 23, 27, 31, 33, 37, 45, 46)

5A I Not used 30A

1 Power windows (see also fuse 33)

5A ~ Engine control module (see also f use 28) Heating and A/C (IHKR E36)(see also fuse 20, 23, 31, 37, 39, 41)

17 I 18

Headlights/foglights (see also fuse 11, 12, 23, 25, 29, 30)

I Not used 15A

1 Fuel pump

19 I

15A I Not used

30A ~ Heating and A/C (IHKR E36)(see also fuse 16, 23, 31, 37, 39, 41) Park ventilation

FUSE POSITION TABLES

Protected Circuit

Multi-function clock (see also fuse 27, 31, 45, 46) Headlights/foglights (see also f use 11, 12, 15, 25, 29, 30) Heated seats (see also fuse 4) Heating and A/C (IHKR E36)(see also fuse 16, 20, 31, 37, 39, 41) Instrument cluster (see also fuse 27, 31, 46) On-Board Computer (see also fuse 11, 12, 27, 31, 33, 37, 45, 46) Rear window defogger (see also fuse 6) Turn signals/hazard lights (see also fuse 34) Headlights/foglights (see also fuse 11, 12, 15, 23, 29, 30) Instrument illumination (see also fuse 22, 33, 37)

ELECTRICAL COMPONENT LOCATIONS Table c. 1993 E36 Fuse Positions fuse

1 Rating 1 Protected Circuit

10A

Cellular telephone (see also fuse 43) Glove compartment IighUcassette compartment/ashtray light/charging socket/cigar lighter (see also fuse 32, 37, 44) Interior lights (also see fuse 43) License plate/luggage compartment lights (see also fuse 37) Instrument illumination (see also fuse 22, 25, 37) On-Board Computer (see also f use 11, 12, 23, 27, 31, 37, 45, 46) Park/taillights (see also fuse 22, 37) Power windows (see also f use 14)

15A

Crash control module Turn signals/hazard lights (see also fuse 23)

35 1

25A 1 Central locking (ZVM II) (see also fuse 7, 43)

36 1

30A 1 Wiper/washer (see also fuse 37, 44, 45)

10A

38 1

30A 1 ABS (see also f use 10, 21, 27, 46)

7.5A

40 1

30A 1 Power seats (see also fuse 5)

30A ~ Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 37, 39) Radiator auxiliary fan

42 1

7.5A 1 Airbag (SRS) (see also fuse 43)

610-23

Table c. 1993 E36 Fuse Positions fuse

Rating

15A

Protected Circuit ABS (see also fuse 10, 21, 27, 38) Brake lights Multi-function clock (see also fuse 23, 27, 31, 45) Cruise control (see also fuse 28) Electronic transmission control (A4S 310R) (see also fuse 26, 28) Instrument cluster (see also fuse 23, 27, 31) On-Board Computer (see also fuse 11, 12, 23, 27, 31, 33, 37, 45)

WARNING Fuse designations and locations are subject to change, and may vary from car to car, depending on options . Ifquestionsarise, pleaserememberthatan authorized BMW dealer is the best source for the most accurate and up-to-date information .

Glove compartment light/cassette compartmenUashtray IighUcharging socket/cigar lighter (see also fuse 32, 33, 44) Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 39, 41) Instrument illumination (see also fuse 22, 25, 33) License plate/luggage compartment lights (see also fuse 33) On-Board Computer (see also fuse 11, 12, 23, 27, 31, 33, 45, 46) Park/taillights (see also fuse 22, 33) Wiper/washer (see also fuse 36, 44, 45) Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 37, 41)

Anti-theft system (Alpíne) (see also fuse 8) Airbag (SRS) (see also fuse 42) Cellular telephone (see also fuse 33) Central locking (ZVM II) (see also f use 7, 35) Interior lights (also see fuse 33)

15A

Glove compartment IighUcassette compartment/ashtray IighUcharging sockeUcigar lighter (see also fuse 32, 33, 37) Sound system (see also fuse 9) Wiper/washer (see also fuse 36, 37, 45)

7 .5A

Multi-function clock (see also fuse 23, 27, 31, 46) On-Board Computer (see also f use 11, 12, 23, 27, 31, 33, 37, 46) Wiper/washer (see also fuse 36, 37, 44)

FOSE POSITION TABLES

ELECTRICAL COMPONENT LOCATIONS

610-24

Fuses 31-46 ------------

Table d. 1994 E36 Fuse Positions

Fuses1-20

fuse

1 Rating 1 Protected Circuit

5A ~ Engine control module (see also f use 28) Heating and A/C (IHKR E36)(see also fuse 20, 23, 31, 37, 39, 41)

17 I

10A I Not used

Fuses 21-30

Table d. 1994 E36 Fuse Positions Rating

Protected Circuit

30A

Power sunroof

15A

Not used

30A

Headlight washer (also see f use 37)

15A

Heated seats (see also fuse 23)

30A

Power seats (see also fuse 40)

20A

Rear window defogger/blower (see also f use 23)

Central body electronics (ZKE IV) (convertible only) (see also fuse 33, 43) Central locking (see also fuse 35, 43) Convertible roof (see also fuse 35, 43) Rol¡-over protection (see also f use 35, 42, 43)

8 I

15A I Horn

9 (

20A 1 Sound system (see also fuse 44)

30A

ABS (see also fuse 21, 38, 46) AST (see also fuse 21, 38)

7 .5A

Headlights/foglights (see also fuse 12, 15, 23, 25, 29, 30) On-Board Computer (see also fuse 12, 23, 27, 31, 33, 37, 45, 46)

7.5A

Headlights/foglights (see also fuse 11, 15, 23, 25, 29, 30) On-Board Computer (see also fuse 11, 23, 27, 31, 33, 37, 45, 46)

13 I

5A I Not used

14 1

30A 1 Front power windows

15A

1 Fuel pump

30A

1 Rear power windows

30A

Blower motor Heating and A/C (IHKR E36) (see also fuse 16, 23, 31, 37, 39, 41) Park ventilation

ABS (see also fuse 10, 38, 46) AST (see also fuse 10, 38)

Instrument illumination (see also f use 25, 37) Park/taillights (see also fuse 33, 37)

Headlights/foglights (see also fuse 11, 12, 15, 25, 29, 30) Heated seats (see also fuse 4) Heating and A/C (IHKR E36)(see also fuse 16, 20, 31, 37, 39, 41) Instrument cluster (see also f use 27, 31, 46) On-Board Computer (see also f use 11, 12, 27, 31, 33, 37, 45, 46) Rear window defogger/blower (see also fuse 6) Turn signais/hazard lights (see also fuse 34)

24 I

10A I Power mirrors

5A ~ Headlights/foglights (see also fuse 11, 12, 15, 23, 29, 30) Instrument illumination (see also fuse 22, 37)

10A ~ Back-up lights Electronic transmission control (A4S 310R) (see also f use 26, 46)

5A ~ Instrument cluster (see also fuse 23, 31, 46) On-Board Computer (see also f use 11, 12, 23, 31, 33, 37, 45, 46)

Cruise control (see also fuse 46) Engine control module (see also fuse 16) Starting system Electronic transmission control (A4S 310R) (see also fuse 26, 46)

7.5A

Headlights/foglights (see also fuse 11, 12, 15, 23, 25, 30)

7.5A

Headlights/foglights (see also fuse 11, 12, 15, 23, 25)

Multi-function clock Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 37, 39, 41) Instrument cluster (see also fuse 23, 27, 46) On-Board Computer (see also fuse 11, 12, 23, 27, 33, 37, 45, 46)

0013034

Fuse positions 1-46 in front power distribution box

fuse

Headlights/foglights (see also fuse 11, 12, 23, 25, 29, 30)

30A 1 Cigar lighterlashtray lights

FOSE POSITION TABLES

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL COMPONENT LOCATIONS Table d. 1994 E36 Fuse Positions fuse

1 Rating 1 Protected Circuit

10A

Central body electronics (ZKE IV) (see also Puse 7, 43) Charging socket Interior lights (also see fuse 43) License platelluggage compartment lights (see also fuse 37) On-Board Computer (see also fuse 11, 12, 23, 27, 31, 37, 45, 46) Park/taillights (see also fuse 22, 37) Telephone (see also fuse 43)

15A

Crash control module Turn signals/hazard lights (see also fuse 23)

25A ~ Central locking (see also fuse 7, 43) Convertible roof (see also fuse 7, 43) Roll-over protection (see also fuse 7, 42, 43)

36 j

30A 1 Wiper/washer (see also fuse 37, 44, 45)

10A

Cassette compartment light Engine compartment light Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 39, 41) Instrument illumínation (see also fuse 22, 25) License plate/luggage compartment lights (see also f use 33) On-Board Computer (see also fuse 11, 12, 23, 27, 31, 33, 45, 46) Park/taillights (see also fuse 22, 33) Wiper/washer (see also fuse 36, 44, 45)

30A

ABS (see also fuse 10, 21, 46) AST (see also fuse 10, 21)

7 .5A

Heating and A/C (IHKR E36) (see also fuse 16, 20, 23, 31, 37, 41)

30A

610-25

Table d. 1994 E36 Fuse Positions fuse 46

1 Rating 1 Protected Circuit 15A

ABS (see also fuse 10, 21, 38) Brake lights Multi-function clock (see also fuse 23, 27, 31, 45) Cruise control (see also fuse 28) Electronic transmission control (A4S 310R) (see also fuse 26, 28) Instrument cluster (see also fuse 23, 27, 31) On-Board Computer (see also fuse 11, 12, 23, 27, 31, 33, 37, 45)

WARNING Fuse designations and locations are subject to change and may vary from car to car, depending on options . If questions arise, please remember that an authorized BMW dealer is the best source for the most accurate and up-to-date information.

1 Power seats (see also fuse 5)

30A ~ Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 37, 39) Radiator auxiliary fan

7.5A

Airbag (SRS) (see also fuse 43) Roll-over protection (see also f use 7, 35, 43)

Anti-theft system (Alpine) Airbag (SRS) (see also fuse 42) Central body electronics (ZKE IV) (see also fuse 7, 33) Central locking (see also fuse 7, 35) Convertible roof (see also fuse 7, 35) Interior lights (also see fuse 33) Rol¡-over protection (see also fuse 7, 35, 42) Telephone (see also fuse 33)

15A ~ Glove compartment light Sound system (see also f use 9) Wiper/washer (see also fuse 36, 37, 45)

7 .5A ~ On-Board Computer (see also fuse 11, 12, 23, 27, 31, 33, 37, 46) Wiper/washer (see also fuse 36, 37, 44)

FOSE POSITION TABLES

ELECTRICAL COMPONENT LOCATIONS

610-26

Fuses 31-46 -------------

Table e. 1995 E36 Fuse Positions

Fuses1-20

fuse

1 Rating 1 Protected Circuit

5A ~ Engine control module (see also fuse 28, 39) Heating and A/C (IHKR E36)(see also fuse 20, 23, 31, 37, 39, 41)

10A

Fuses 21-30

Table e. 1995 E36 Fuse Positions fuse

Rating

Protected Circuit

30A

Power sunroof

15A

Not used

30A

Headlight washer (also see f use 37)

15A

Heated seats (see also fuse 23)

30A

Power seats (see also fuse 40)

20A

Rear window defogger/blower (see also f use 23)

Central body electronics (ZKE IV) (convertible only) (see also fuse 14, 31, 33, 35,43) Central locking (see also fuse 26, 28, 35) Convertible roof (see also fuse 27, 35, 42, 43) Interior lights (also see fuse 33, 43) Roll-over protection (see also fuse 35, 42, 43)

8 I 9

15A I Horn 20A

1 Sound system (see also fuse 33, 44)

30A

ABS (see also fuse 21, 23, 27, 38, 46, 47) AST (see also fuse 21, 26, 27, 38, 46)

7 .5A

Headlights/foglights (see also fuse 12, 15, 17, 23, 25, 29, 30) On-Board Computer (see also fuse 12, 23, 27, 31, 33, 37, 45, 46)

7 .5A

Headlights/foglights (see also fuse 11, 15, 17, 23, 25, 29, 30) On-Board Computer (see also fuse 11, 23, 27, 31, 33, 37, 45, 46)

13 I

5A I Not used

30A ~ Central body electronics (ZKE IV) (see also fuse 7, 14, 31, 33, 35, 43) Front power Windows

15A

Headlights/foglights (see also fuse 11, 12, 17, 23, 25, 29, 30)

FOSE POSITION TABLES

15A

1 Fuel pump

30A

1 Rear power Windows

30A

Blower motor Heating and A/C (IHKR E36) (see also fuse 16, 23, 31, 37, 39, 41) Park ventilation

ABS (see also fuse 10, 23, 27, 38, 46, 47) AST (see also fuse 10, 26, 27, 38, 46)

5A ~ Instrument illumination (see also f use 25, 33, 37) Park/taillights (see also fuse 33, 37)

24 I

10A I Power mirrors

Headlights/foglights (see also fuse 11, 12, 15, 17, 23, 29, 30) Instrument illumination (see also fuse 22, 33, 37)

10A

AST (see also fuse 10, 21, 27, 38, 46) Back-up lights Central locking (see also fuse 7, 28, 35) Electronic transmission control (A4S 310R/Z) (see also tuse 28, 46) Multi-function clock (see also fuse 23, 27, 31, 45,46) On-Board Display (see also fuse 23, 27, 31, 45,46) Starting system (see also fuse 28)

ABS (see also fuse 10, 21, 23, 38, 46, 47) AST (see also fuse 10, 21, 26, 38, 46) Convertible roof (see also fuse 7, 35, 42, 43) Instrument cluster (see also f use 23, 31, 46) Multi-function clock (see also fuse 23, 26, 31, 45,46) On-Board Computer (see also fuse 11, 12, 23, 26, 31, 33, 37, 45, 46) On-Board Display (see also f use 23, 31, 45, 46)

0013034

Fuse positions 1-46 in front power distribution box

Headlights/foglights (see also fuse 11, 12, 15, 23, 25, 29, 30)

ABS (see also fuse 10, 21, 27, 38, 46) Headlights/foglights (see also fuse 11, 12, 15, 17, 25, 29, 30) Heated seats (see also fuse 4) Heating and A/C (IHKR E36)(see also fuse 16, 20, 31, 37, 39, 41) Instrument cluster (see also f use 27, 31, 46) Multi-function clock (see also fuse 26, 27, 31, 45,46) On-Board Computer (see also fuse 11, 12, 27, 31, 33, 37, 45, 46) On-Board Display (see also fuse 26, 27, 31, 45,46) Rear window defogger/blower (see also f use 6) Turn signals/hazard lights (see also f use 34)

ELECTRICAL COMPONENT LOCATIONS Table e. 1995 E36 Fuse Positions I Rating 1 Protected Circuit

fuse 28

Central locking (see also fuse 7, 26, 35) Cruise control (see also fuse 46) Engine control module (see also f use 16, 39) Electronic transmission control (A4S 310R/Z) (see also fuse 26, 46) Starting system (see also fuse 26)

7.5A

Headlights/foglights (see also fuse 11, 12, 15, 17, 23, 25, 30)

7.5A

Headlights/foglights (see also fuse 11, 12, 15, 17, 23, 25, 29)

Central body electronics (ZKE IV) (see also fuse 7, 14, 33, 35, 43) Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 37, 39, 41) Instrument cluster (see also fuse 23, 27, 46) Multi-function clock (see also fuse 23, 26, 27, 45,46) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 33, 37, 45, 46) On-Board Display (see also fuse 23, 27, 45, 46)

30A 1 Cigar lighter/ashtray lights 10A

Central body electronics (ZKE IV) (see also fuse 7, 14, 31, 35, 43) Charging socket Door lock heating Instrument illumination (see also fuse 22, 25, 37) Interior lights (also see fuse 7, 43) License plate/luggage compartment lights (see also fuse 37) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 31, 37, 45, 46) Park/taillights (see also f use 22, 37) Sound system (see also fuse 9, 44) Telephone (see also fuse 43)

15A

Crash control module Turn signals/hazard lights (see also fuse 23)

25A

Central body electronics (ZKE IV) (see also fuse 7, 14, 31, 33,43) Central locking (see also fuse 7, 26, 28) Convertible roof (see also fuse 7, 27, 42, 43) Rol¡-over protection (see also fuse 7, 42, 43)

36 37

30A 1 Wiper/washer (see also fuse 37, 44, 45) 10A

30A

Cassette compartment light Engine compartment light Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 39, 41) Instrument illumination (see also fuse 22, 25, 33) License plate/luggage compartment lights (see also fuse 33) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 31, 33, 45, 46) Park/taillights (see also fuse 22, 33) Wiper/washer (Canada only) (see also f use 36, 44, 45) ABS (see also fuse 10, 21, 23, 27, 46, 47) AST (see also fuse 10, 21, 26, 27, 46)

610-27

Table e. 1995 E36 Fuse Positions fuse

Rating

Protected Circuit

7.5A ~ Engine control module (see also fuse 16, 28) Heating and A/C (IHKR E36) (see also fuse 16, 20, 23, 31, 37, 41)

30A 1 Power seats (see also fuse 5)

30A ~ Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 37, 39) Radiator auxiliary fan

7 .5A ~ Airbag (SRS) (see also fuse 43) Convertible roof (see also fuse 7, 27, 35, 43) Rol¡-over protection (see also fuse 7, 35, 43) Anti-theft system (Alpine) (see also fuse 47) Airbag (SRS) (see also fuse 42) Central body electronics (ZKE IV) (see also fuse 7, 14, 31, 33, 35) Central locking (see also fuse 7, 35) Convertible roof (see also fuse 7, 27, 35, 42) Interior lights (also see fuse 7, 33) Roll-over protection (see also fuse 7, 35, 42) Telephone (see also fuse 33)

15A ~ Glove compartment light Sound system (see also fuse 9, 33) Wiper/washer (see also fuse 36, 37, 45)

7.5A

Multi-function clock (see also fuse 23, 26, 27, 31,46) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 31, 33, 37, 46) On-Board Display (see also fuse 23, 27, 31, 46) Wiper/washer (Canada only) (see also fuse 36, 37, 44)

15A

ABS (see also fuse 10, 21, 23, 27, 38, 47) AST (see also fuse 10, 21, 26, 27, 38) Brake lights Cruise control (see also fuse 28) Electronic transmission control (A4S 310R) (see also fuse 26, 28) Instrument cluster (see also fuse 23, 27, 31) Multi-function clock (see also fuse 23, 26, 27, 31,45) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 31, 33, 37, 45) On-Board Display (see also fuse 23, 27, 31, 45)

15A

ABS (see also fuse 10, 21, 23, 27, 38, 46) Anti-theft system (Alpine) (see also fuse 43)

40A

Not used

WARNING " Fuse designations and locations are subject to change, and may vary from car to car, depending on options . lf questions arise, please remember that an authorized BMW dealer is the best source for the most accurate and up-to-date information . " To locate fuses 47-48, refer to Fuse and Relay Positions in this repair group .

FOSE POSITION TABLES

610-28

ELECTRICAL COMPONENT LOCATIONS Table f. 1996 E36 Fuse Positions

Fuses 1-20

Fuses 31-46

kLírcoo)]

fuse

7aMaz

Fuses 21-30

Table f. 1996 E36 Fuse Positions Rating

Protected Circuit

30A

Power sunroof (see also fuse 13)

15A

Not used

30A

Headlight washer (also see fuse 37)

15A

Heated seats (see also fuse 23)

30A

Power seats (see also fuse 40)

20A

Rear window defogger/blower (see also fuse 23)

Central body electronics (ZKE IV) (convertible only) (see also f use 14, 33, 35, 43) Central locking (see also fuse 26, 28, 35) Convertible roof (see also fuse 27, 35, 42, 43) Interior lights (also see fuse 33, 43) Rol¡-oven protection (see also fuse 35, 42, 43)

8 I

15A I Horn

9 1

20A 1 Sound system (see also fuse 44)

30A

ABS (see also fuse 21, 23, 27, 38, 46, 47) AST (see also fuse 21, 26, 27, 38, 46)

7.5A

Headlights/foglights (see also fuse 12, 15, 17, 23, 25, 29, 30) On-Board Computer (see also fuse 12, 23, 27, 31, 33, 37, 45, 46)

7.5A

Headlights/foglights (see also fuse 11, 15, 17, 23, 25, 29, 30) On-Board Computer (see also fuse 11, 23, 27, 31, 33, 37, 45, 46)

1 Power sunroof (see also fuse 1)

30A ~ Central body electronics (ZKE IV) (see also fuse 7, 14, 33, 35, 43) Front power windows

15A

Headlights/foglights (see also fuse 11, 12, 17, 23, 25, 29, 30)

FUSE POSITION TABLES

5A ~ Engine control module (see also f use 28, 39) Heating and A/C (IHKR E36)(see also fuse 20, 23, 31, 37, 39, 41, 48)

10A

1 19 1

15A

30A

Blower motor Heating and A/C (IHKR E36) (see also fuse 16, 23, 31, 37, 39, 41, 48) Park ventilatíon

ABS (see also fuse 10, 23, 27, 38, 46, 47) AST (see also fuse 10, 26, 27, 38, 46)

Instrument illumínation (see also fuse 25, 33, 37)

ABS (see also fuse 10, 21, 27, 38, 46) Headlights/foglights (see also fuse 11, 12, 15, 17, 25, 29, 30) Heated seats (see also fuse 4) Heating and A/C (IHKR E36)(see also fuse 16, 20, 31, 37, 39, 41, 48) Instrument cluster (see also fuse 27, 31, 46) Multi-function clock (see also fuse 26, 27, 31, 45,46) On-Board Computen (see also f use 11, 12, 27, 31, 33, 37, 45, 46) On-Board Display (see also fuse 26, 27, 31, 45,46) Rear 6) window defogger/blower (see also fuse

Headlights/foglights (see also fuse 11, 12, 15, 23, 25, 29, 30)

1 Fuel pump 30A 1 Rear power windows

0013034

Fuse positions 1-46 in front power distribution box

fuse

1 Rating 1 Protected Circult

Turn signals/hazard lights (see also fuse 34) 24 I

10A I Power mirrors

Headlights/foglights (see also fuse 11, 12, 15, 17, 23, 29, 30) Instrument illumination (see also fuse 22, 33, 37)

10A

Airbag (SRS) (see also fuse 43) AST (see also f use 10, 21, 27, 38, 46) Back-up lights Central locking (see also fuse 7, 28, 35) Electronic transmission control (A4S 310R/Z) (see also f use 28, 46) Multi-function clock (see also fuse 23, 27, 31, 45,46) On-Board Display (see also fuse 23, 27, 31, 45,46) Starting system (see also fuse 28) .

ABS (see also fuse 10, 21, 23, 38, 46, 47) AST (see also fuse 10, 21, 26, 38, 46) Convertible roof (see also f use 7, 35, 42, 43) Instrument cluster (see also fuse 23, 31, 46) Multi-function clock (see also fuse 23, 26, 31, 45,46) On-Board Computer (see also fuse 11, 12, 23, 26, 31, 33, 37, 45, 46) On-Board Display (see also fuse 23, 31, 45, 46)

ELECTRICAL COMPONENT LOCATIONS

Table f. 1996 E36 Fuse Positions

Table f. 1996 E36 Fuse Positions fuse

Rating

Protected Circuit Central locking (see also fuse 7, 26, 35) Cruise control (see also fuse 46) Engine control module (see also fuse 16, 39) Electronic transmission control (A4S 310R/Z) (see also f use 26, 46) Driveaway protection (EWS II) (see also fuse 31,46) Starting system (see also f use 26)

7.5A

Headlights/foglights (see also fuse 11, 12, 15, 17, 23, 25, 30)

7 .5A

Headlights/foglights (see also fuse 11, 12, 15, 17, 23, 25, 29)

Driveaway protection (EWS II) (see also fuse 28,46) Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 37, 39, 41, 48) Instrument cluster (see also fuse 23, 27, 46) Multi-function clock (see also fuse 23, 26, 27, 45,46) On-Board Computer (see also f use 11, 12, 23, 26, 27, 33, 37, 45, 46) On-Board Display (see also fuse 23, 27, 45, 46) ,

30A

10A

1 Cigar lighter/ashtray lights Central body electronics (ZKE IV) (see also f use 7, 14, 35, 43) Charging socket Engine compartment light (also see fuse 37) Instrumenf illumination (see also fuse 22, 25, 37) Interior lights (also see fuse 7, 43) License plate/luggage compartment lights (see also fuse 37) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 31, 37, 45, 46) Park/taillights (see also fuse 37) Telephone (see also fuse 43)

15A

Crash control module Turn signals/hazard lights (see also fuse 23)

25A

Central body electronics (ZKE IV) (see also fuse 7, 14, 33, 43) Central locking (see also fuse 7, 26, 28) Convertible roof (see also fuse 7, 27, 42, 43) Roll-over protection (see also fuse 7, 42, 43)

36 37

30A 10A

30A

1 Wiper/washer (see also fuse 44, 45) Cassette compartment light Engine compartment light (also see fuse 33) Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 39, 41, 48) Instrument illumination (see also fuse 22, 25, 33) License plate/luggage compartment lights (see also fuse 33) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 31, 33, 45, 46) Park/taillights (see also fuse 33) ABS (see also fuse 10, 21, 23, 27, 46, 47) AST (see also f use 10, 21, 26, 27, 46)

610-29

fuse

1 Rating 1 Protected Circuit

7 .5A ~ Engine control module (see also fuse 16, 28) Heating and A/C (IHKR E36) (see also fuse 16, 20, 23, 31, 37, 41, 48)

40 1

30A

30A ~ Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 37, 39, 48) Radiator auxiliary fan

7 .5A ~ Airbag (SRS) (see also fuse 26, 43) Convertible roof (see also fuse 7, 27, 35, 43) Rol¡-over protection (see also f use 7, 35, 43)

1 Power seats (see also fuse 5)

Anti-theft system (Alpine) (see also fuse 47) Airbag (SRS) (see also fuse 26, 42) Central body electronics (ZKE IV) (see also fuse 7, 14, 33, 35) Central locking (see also fuse 7, 35) Convertible roof (see also f use 7, 27, 35, 42) Interior lights (also see fuse 7, 33) Rol¡-over protection (see also f use 7, 35, 42) Telephone (see also fuse 33)

15A ~ Glove compartment light Sound system (see also fuse 9) Wiper/washer (see also fuse 36, 37, 45)

7 .5A

Multi-function clock (see also fuse 23, 26, 27, 31,46) On-Board Computer (see also f use 11, 12, 23, 26, 27, 31, 33, 37, 46) On-Board Display (see also fuse 23, 27, 31, 46) Wiper/washer (see also f use 36, 44)

15A

ABS (see also fuse 10, 21, 23, 27, 38, 47) AST (see also fuse 10, 21, 26, 27, 38) Brake lights Cruise control (see also fuse 28) Driveaway protection (EWS II) (see also fuse 28,31) Electronic transmission control (A4S 310R) (see also fuse 26, 28) Instrument cluster (see also fuse 23, 27, 31) Multi-function clock (see also fuse 23, 26, 27, 31,45) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 31, 33, 37, 45) On-Board Display (see also fuse 23, 27, 31, 45)

15A

ABS (see also fuse 10, 21, 23, 27, 38, 46) Anti-theft (Alpine) (see also fuse 43)

40A

Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 37, 39, 41)

WARNING " Fuse desfgnations and locations are subject to change and may vary from car to cal depending on options. If questions arise, please remember that an authorized BMW dealer is the best source for the mostaccurate and up-to-date information. " To locate fuses 47-48, refer to Fuse Positions in this repair group.

FOSE POSITION TABLES

610-30

ELECTRICAL COMPONENT LOCATIONS

Fuses 31-46 --------------

Table g . 1997-1998 E36 Fuse Positions

Fuses 1-20

fuse

1 Rating 1 Protected Circuit

18 Fuses 21-30

0013034

Fuse positions 1-46 in front power distribution box

Table g . 1997-1998 E36 Fuse Positions fuse

Rating

Protected Circuit

1 I

30A I Power sunroof

Engine controls DME M5 .2 (see also fuses 16, 18, 39, 46)

30A

Wiper/washer module (see also fuse 36, 37, 44)

1 5 1 4

10A 15A

30A

Blower motor Heating and A/C (IHKR E36) (see also fuse 16, 23, 31, 37, 39, 48) Park ventilation

ABS (see also fuse 10, 27, 38, 46) AST (see also fuse 10, 27, 38, 46)

Instrument illumination (see also fuse 25, 33, 37)

Antenna (see also fuse 6) Headlights/foglights (see also fuse 11, 12, 15, 25, 29, 30) Heated seats (see also fuse 4) Heating and A/C (IHKR E36)(see also fuse 16, 20, 31, 39, 41, 48) Instrument cluster (see also fuse 27, 31,45, 46) Multi-function clock (see also fuse 26, 27, 31, 45,46) On-Board Computer (see also fuse 11, 12, 27, 31, 33, 37, 45, 46) On-Board Display (see also fuse 26, 27, 31, 45,46) Rear window defogger/blower (see also f use 6,43) Turn signals/hazard lights (see also fuse 34)

10A ~ Convertible roof (see also fuse 7, 27, 42, 43, 49) Power mirrors

1 Heated seats (see also fuse 23) 30A 1 Power seats (see also fuse 40) 15A

15A I Horn 20A 1 Sound system (see also fuse 33, 43, 44)

Engine control DME M5 .2 (see also fuse 2, 16, 39, 46) Engine control MS 41 .1(see also fuse 16, 39, 46,50)

5A ~ Central locking (see also fuse 28, 31, 35, 45) Convertible roof (see also fuse 24, 27, 42, 43,49)

1 Not used

30A j Power windows (see also fuse 14

20A ~ Rear window defogger/blower (see also fuse 23,43) Antenna (see also fuse 23)

Engíne control DME M5 .2 (see also fuse 2, 18, 39, 46) Engine control DME MS 41 .1 (see also fuse 18, 39, 46, 50) Heating and A/C (IHKR E36) (see also fuse 20, 23, 31, 39, 41, 48)

30A

ABS (see also fuse 21, 27, 38, 46) AST (see also fuse 21,27, 38, 46)

7.5A

Headlights/foglights (see also fuse 12, 15, 23, 25, 29, 30) On-Board Computer (see also fuse 12, 23, 26, 27, 31, 33, 37, 45, 46)

Headlights/foglights (see also fuse 11, 12, 15, 23, 29, 30) Instrument illumination (see also fuse 22, 33, 37)

7.5A

Headlights/foglights (see also fuse 11, 15, 23, 25, 29, 30) On-Board Computer (see also f use 11, 23, 26, 27, 31, 33, 37, 45, 46)

10A

Back-up lights Electronic transmission control (A4S 310R/Z) (see also fuse 28, 46) Electronic transmission control (A5S 310Z) (see also fuses 28, 46) Multi-function clock (see also fuse 23, 27, 31, 45,46) On-Board Computer (see also fuse 11, 12, 23, 27, 31, 33, 37, 45, 46)

13 I

5A I Not used

30A ~ Central body electronics (ZKE IV) (see also fuse 33, 35, 43) Power windows (see also fuse 19)

15A

Headlights/foglights (see also fuse 11, 12, 23, 25, 29, 30)

FUSE POSITION TABLES

ELECTRICAL COMPONENT LOCATIONS Table g. 1997-1998 E36 Fuse Positions fuse

1 Rating 1 Protected Circuit

Airbag (SRS) (see also fuse 42) ABS (see also fuse 10, 21, 38, 46) AST (see also fuse 10, 21, 38, 46) Convertible roof (see also fuses 7, 24, 42, 43,49) Instrument cluster (see also fuse 23, 31, 45, 46) Multi-function clock (see also fuse 23, 26, 31, 45,46) On-Board Computer (see also fuse 11, 12, 23, 26, 31, 33, 37, 45, 46) On-Board Display (see also fuse 23, 27, 31, 45,46)

fuse

1 Rating 1 Protected Circuit 10A

Central locking (see also fuse 7, 31, 35, 45) Cruise control (see also fuse 46) Electronic transmission control (A4S 310R/Z) (see also f use 26, 46) Electronic transmission control (A5S 310Z) (see also (uses 26, 46) Driveaway protection (EWS II) (see also fuse 31,45) Starting system (see also fuse 31, 45)

Ashtray light (see also fuses32, 37, 44) Cassette compartment (see also fuses 32, 37,44) Cellular phone (see also fuse 43) Central body electronics (ZKE IV) (see also fuse 14, 35, 43) Charging socket (see also fuses 32, 37,44) Cigar lighter (see also fuses 32,37,44) Instrument illumination (see also fuse 22, 25, 37) Interior ¡ights (see also fuse 43) Glove compartment light (see also fuse 32, 37,44) License plate/luggage compartment lights (see also fuse 37) Luggage compartment light (see also f use 37) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 31, 37, 45, 46) Park/taillights (see also fuse 37) Sound system (see also fuses 9, 43,44)

15A

Crash control module Turn signals/hazard lights (see also fuse 23)

25A ~ Central body electronics (ZKE IV) (see also fuse 14, 33, 43) Central locking (see also f use 7, 28, 31,45)

30A

Headlight washers (see also fuses 3, 37) Wiper/washer (see also fuse 3, 37, 44)

10A

Ashtray light (see also (uses 32, 33, 44) Cassette compartment light (see also fuses 32, 33, 44) Charging socket (see also fuses 32, 33, 44) Cigar lighter (see also f uses 32, 33, 44) Glove compartment light (see also fuses 32, 33,44) License plate/luggage compartment lights (see also fuse 33) Instrument illumination (see also fuses 22, 25,33) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 31, 33, 45, 46) Park/taillights (see also fuse 33) Wiper washer module (see also fuses 3, 36, 44)

30A

ABS (see also fuse 10, 21, 27, 46) AST (see also fuse 10, 21, 27, 46)

7 .5A

Engine control DME M5 .2 (see also fuse 16,18, 46) Engine control DME MS 41 .1 (see also fuses 16, 18, 46, 50) Heating and A/C (IHKR E36) (see also fuse 12, 20, 23, 31, 41, 48)

30A

Power seats (see also fuse 5)

30A ~ Heating and A/C (IHKR E36) (see also fuse 16, 20, 23, 31, 39, 48) Radiator auxiliary fan

7.5A

Headlights/foglights (see also fuse 11, 12, 15, 23, 25, 30)

7 .5A

Headlights/foglights (see also fuse 11, 12, 15, 17, 23, 25, 29)

Central locking (see also fuse 7, 28, 35, 45) Driveaway protection (EWS II) (see also fuse 28,45) Heating and A/C (IHKR E36) (see also fuse 16, 20, 23, 39, 41, 48) Instrument cluster (see also fuse 23, 27,45, 46) Multi-function clock (see also fuse 23, 26, 27, 45,46) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 33, 37, 45, 46) On-Board Display (see also f use 23, 26, 27, 31, 45, 46) Starting system (see also fuses 28, 45)

30A

Table g. 1997-1998 E36 Fuse Positions 33

610-31

Cassette compartment (see also fuses 33, 37,44) Charging socket (see also fuses 33, 37, 44) Cigar lighter/ashtray lights (see also fuses 33, 37,44) Glove compartment light (see also fuses 33, 37,44)

Airbag (SRS) (see also fuse 27) Convertible roof (see also fuse 7, 24, 27, 43, 49) Rol¡-over protection (see also fuse 43)

FOSE POSITION TABLES

610-32

ELECTRICAL COMPONENT LOCATIONS

Table g .

fuse

Rating

1997-1998 E36

Fuse

Positions

Protected Circult Anti-theft system (Alpine) (see also f use 47) Cellular phone (see also fuse 33) Central body electronics (ZKE IV) (see also fuse 14, 33, 35) Convertible roof (see also fuse 7, 24, 27, 42, 49) Interior lights (also see fuse 33) Rear window defogger/blower (see also fuse 6,23) Roll-over protection (see also fuse 42) Sound system (see also fuses 9, 33, 44)

15A

Ashtray light (see also f uses 32, 33, 37) Cassette compartment light (see also fuses 32, 33, 37) Charging socket (see also fuses 32, 33, 37) Cigar lighter (see also fuses 32, 33, 37) Glove compartment light (see also f uses 32, 33,37) Sound system (see also fuse 9, 33, 43) Wiper/washer (see also fuse 3, 36, 37)

7 .5A

Central locking (see also fuses 7, 28, 31, 35) Drive-away protection (EWS II) (see also fuse 28, 29, 31) Instrument cluster (see also f uses 23, 27, 31, 46) Multi-function clock (see also f use 23, 26, 27, 31,46) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 31, 33, 37, 46) On-Board Display (see also fuse 23, 27, 31, 46) Starting system (see also fuses 28, 31)

15A

ABS (see also fuse 10, 21, 27, 38) AST (see also fuse 10, 21, 27, 38) Brake lights Cruise control (see also fuse 28) Electronic transmission control (A4S 310R) (see also fuse 26, 28) Electronic transmission control (A5S 310Z) (see also f use 26, 28) Engine control DME M5 .2 (see also fuses 2, 16, 18, 39) Engine control DME MS 41 .1 (see also fuses 16, 18, 39, 50) Instrument cluster (see also fuse 23, 27, 31, 45) Multi4unction clock (see also fuse 23, 26, 27, 31,45) On-Board Computer (see also fuse 11, 12, 23, 26, 27, 31, 33, 37, 45)

15A

WARNING" Fuse designations and locations are subject to change and may vary from car to car, depending on options . If questions arise, please remember that an authorized BMWdealer is the best source for the most accurate and up-to-date information .

" To locate fuses 47-50, refer to Fuse Positions in this repair group.

Anti-theft system (see also fuse 43)

40A

Heating and A/C (IHKR E36)(see also fuse 16, 20, 23, 31, 39, 41)

20A

Convertible roof (see also fuses 7, 24, 27, 42,43)

Engine control DME MS 41 .1 (see also fuses 16, 18, 39, 46)

FUSE POSITION TABLES

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

WIPERS AND WASHERS

611-1

611 Wipers and Washers GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611-1 WIPER BLADES . . . . . . . . . . . . . . . . . . . . . .611-1

Wiper Blade Cleaning Problems . . . . . . . . . . . 611-1 Wiper blades, replacing . . . . . . . . . . . . . . . . . 611-1 Wiper blade inserts, replacing . . . . . . . . . . . . . 611-2 Wiper arms, removing and installing . . . . . . . . 611-2

WINDSHIELD WIPER ASSEMBLY . . . . . . . 611-3 Windshield wiper assembly, removing and installing (4-door models) . . . . . . . . . . . 611-3 Windshield wiper assembly, removing and installing (2-door models) . . . . . . . . . . . 611-5

GENERAL This repair group covers windshield wiper and washer system repair information . Please note that some procedures are different for 2- and 4-door models . The windshield wiper/washer stalk switch assembly is covered in 612 Switches and Electrical Accessories. Electrical wiring diagrams and relays for the wiper/washer system are covered in Electrical Wiring Diagrams .

WIPER BLADES CA UTION-

Never turn on the wiper blades while the hood is open. Damage to the wiper system and hood may occur. To ensure safety during wiper biade system procedures, remove the windshield wiper fuse. See 610 Electrical Component Locations.

Wiper Blade Cleaning Problems Common cleaning problems with the wipers include streaking or sheeting, water drops after wiping, and blade chatter. Streaking is usually caused when wiper blades are coated with road film or car wash wax . Clean the blades using soapy water. If cleaning does not cure the problem, the blades should be replaced . BMW recommends replacing the wiper blades twice a year, before and after the cold season . Dropsthat remain behind after wiping are usually caused by oil, road film, or diesel exhaust residue on the glass. Use an alcohol or ammonia solution or a non-abrasive cleaner (such as Bon-Ami to clean the windshield .

Windshield wiper motor, removing and installing . . . . . . . . . . . . . . . . .611-8

WINDSHIELD CLEANING SYSTEM . . . . . . 611-9 Windshield spray nozzle, removing and installing . . . . . . . . . . . . . . . . .611-9 Washer fluid reservoir, replacing . . . . . . . . . .611-9 Windshield washer fluid pump, replacing . . . . . . . . . . . . . . . . . . .611-9 Washer fluid level sensor, replacing (models with check control) . . . . . . . . . . . . 611-10

Wiper blade chatter may be caused by dirty or worn blades, or by wiper arms that are out of alignment. Clean the blades and windshield as described above. Adjust the wiper arm so that there is even pressure along the blade, and so that the blade at rest is perpendicular to the windshield . If problems persist, the blades and wiper arms should be replaced .

NOTE-

BMwhas available a special toollgauge (BMWspecial tool no. 00 9210) to align the angle of the wiper arm to the windshield glass .

The wiper blades can be renewed in one of two ways : either by replacing the complete blade or by replacing just the rubber insert . Insert replacement is the most economical method, although over time the wiper blade itself will become worn . One rule of thumb would be to replace just the inserts every second time .

Wiper blades, replacing 1 . Pivot wiper arm off windshield . 2. Position wiper blade approximately perpendicular to wiper arm . 3. Remove wiper blade from wiper arm by depressing retaining tab and sliding blade out of arm. See Fig. 1 .

NOTE-

Some wiper blade versions may have two retaining tabs.

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

611-2

WIPERS AND WASHERS NOTE -

The notched cutouts in the retaining strips should engage the molded notches in the inserts.

5. Slide new insert through wiper blade guides . Lock insert m place at end gudes. ,., \ - -

Wiper arms, removing and installing NOTE-

On 2-door models it may be necessary to raise the hood to the service position . See 410 Fenders, Engine

Hood .

CAUTION-

" Use fender cover to protect windshield. " Remove windshield wiper fuse to prevent accidents.

Fig. 1 . Windshield wiper biade retaining tab. Press in on tab (arrow) to release bfade from arm.

1 . With engine hood in closed position, remove both wiper blades .

4. Installation is reverse of removal. Instan wiper blade to wiper arm until retaining tab can be heard to click into position .

2. Open hood . Remove cap covering wiper arm retaining nuts by inserting a narrow screwdriver biade in slot below cap and prying upward .

Wiper biade inserts, replacing

NOTE -

1 . Remove wiper blade as described earlier. 2. Unhook end of wiper blade insert from wiper arm guides . See Fig. 2.

Marking position of wiper arm on shaft will aid installation .

3 . Using a 13 mm socket, remove wiper arm retaining nut and remove wiper arm . See Fig. 3 .

0011784

Fig. 2. Unhook wiper biade insert from wiper arm guide. If necessary, guide slightly using need1e nose pliers .

3. Pull old insert from wiper arm guides, noting installation position . 4. Remove metal support strips from old insert and instan into slots in new insert, noting installation direction of cutouts in support strips . GENERAL

Fig. 3. Wiper arm retaining nut. (arrow). NOTE -

ft may be necessary to gently rock wiper arm back and forth to loosen arm from shaft.

WIPERS AND WASHERS 4. Installation is reverse of removal. Recheck wiper arm tightening torque after waiting 15 minutes. Tightening Torque " Wiper arm to wiper shaft . . . . . . . . . . 25 Nm (18 ft-Ib)

WINDSHIELD WIPER ASSEMBLY The windshield wiper assembly (linkage and motor) is removed as a single unit. Once the assembly is removed, the wiper motor and other linkage parts can be repaired or replaced . For an illustration of wiper assembly components, see Fig. 4.

611-3

Windshield wiper assembly, removing and installing (4-door modeis) NOTE The wiperarms should be in the parked position before removing the wiper assembly. To avoid damaging the wiper arms and pivots, do not manually slide or force the wiper arms across the windshield.

1 . Disconnect negative (-) cable from battery. CAUTION " Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

Hex nut I

J Wiper motor

0013030

Fig. 4. Windshield wiper motor assembly and related parts. WINDSHIELD WIPER ASSEMBLY

611-4

WIPERS AND WASHERS

2. Remove wiper arms as described earlier. 3. Place engine hood in service position . See 410 Fenders, Engine Hood . 4. Unclip engine bulkhead plenum grille at base of windshield and pulí it away from rubber gasket . See Fig. 5.

Fig. 7. Right side plenum retaining screws (arrows) . 7. On driver's side of air plenum, push aside wiring harness and remove screw retaining plenum . Pull plenum up and remove from engine compartment. See Fig. 8.

Fig. 5. Detach grill clips (arrows) and pull upward .

0012527

5. Remove wiring harness retaining clip from bulkhead in rear of engine bay. Remove screws retaining wiring harness protective cover. See Fig. 6.

001¿534

Fig. 8. Remove screw at A and pull plenum housing upward .

8. On 6-cylinder models : Remove plastic top engine covers. See 110 Engine Removal and Installation . NOTECover ínside edges of cowl panel sheet metal with thick tape to prevent damage during wiperassembly remov-

al.

0012529

Fig. 6. Engine bulkhead wiring harness cover screws (arrows) .

6. On passenger side of air plenum, push aside wiring harness and remove two screws retaining plenum housing. See Fig. 7.

WINDSHIELD WIPER ASSEMBLY

9. Remove large nut and washer at base of wiper arm shafts cowi panel. See Fig. 9. 10. Remove wiper assembly support. See Fig. 10 . 11 . Separate harness at bulkhead connector. See Fig. 11 . 12 . Wrap protective tape around wiper shaft on driver's side to prevent damaging painted metal during removal .

WIPERS AND WASHERS

611-5

14 . Installation is reverse of removal, noting the following: " Install all fasteners finger-tight first. " Once installed, wiper motor should first be run to parked position and switched off. " Next, instaf wiper arms but not blades . " Close hood and fit wiper blades . " Check all electrical harness fittings and sealing grommets for correct reinstallation . Replace any wire ties cut off during removal .

Fig. 9. Wiper shaft nut at cowl (arrow) .

0012533

Tightening Torques " Wiper shaft nut at cowl . . . . . . . . . . . . . 12 Nm (9 ft-Ib) " Wiper support to wiper assembly or to body . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) " Wiper arm to wiper shaft . . . . . . . . . . 25 Nm (18 ft-lb)

Windshield wiper assembly, removing and installing (2-door modeis) NOTEThe wiper arms should be in the parked position before removing the wiper assembly. To avoid damaging the wiper arms and pivots, do not manually sidde or force the wiper arm across the windshield.

1 . Disconnect negative (-)cable from battery.

0012535

Fig . 10. Wiper assembly support bolts (arrows) .

CAUTION" Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii. " Use fender cover to protect windshield.

2. Remove wiper arms as described earlier. 3. Place engine hood in service position . See 410 Fenders, Engine Hood . 4. Remove trim retainers at left and right side and remove air plenum grill . See Fig. 12 . 5. Remove screws retaining wiring harness protective cover. See Fig. 13 . 6. On passenger side of air plenum, push aside wiring harness and remove two screws retaining plenum housing. See Fig. 14 . 0012536

Fig . 11 . Wiper assembly electrical connector (arrow) .

13 . Push wiper arm shaft down into cowl area and maneuver wiper assembly out of cowl .

WINDSHIELD WIPER ASSEMBLY

611- 6

WIPERS AND WASHERS

0012635

Fig . 14 . Right side plenum retaining screws (black arrows) . Note positive leads to main (+) connector (white arrow) . 7 . On driver's side of air plenum, push aside wiring harness and remove screw retaining pienum . Pull plenum up and remove from engine bay. See Fig . 15 .

Fig . 12 . Left side air plenum grill trim retainers (arrows) .

Fig . 15 . Remove screw at A and pull plenum upward . 8. On passenger side of engine compartment bulkhead, remove engine control module (ECM) compartment cover. See Fig . 16.

uu12529

Fig . 13. Engine bulkhead wiring harness cover screws (arrows) .

9 . Disconnect harness connector(s) from ECM and automatic transmission control module (if applicable) . Carefully pull harness and wire loom as far forward as possible . If necessary, disconnect positive leads at main (+) connector. 10 . Remove wiper assembly mounting fasteners . See Fig . 17 .

WINDSHIELD WIPER ASSEMBLY

WIPERS AND WASHERS

0012531

Fig . 16 . Engine control unit (ECM) compartment cover screws (arrows) .

611-7

uu1zbs6

Fig . 18 . Wiper assembly electrical plug (arrow) .

13 . Cover inside edges of cowi panel sheet metal with thick tape to prevent damaging it during wiper assembly removal . 14 . Wrap protective tape around wiper shaft on driver side to prevent damaging sheet metal during removal . 15 . Push wiper arm shaft down into cowi area and maneuver wiper assembly out of cowi . 16 . Installation is reverse of removal, keeping

in mind :

" Install all fasteners finger tight first . " Torque top fasteners in sequence indicated in Fig . 17 . Then tighten wiper assembly support bolts inside air plenum . " Wire tie wiper harness lo wiper assembly support inside plenum . " Once installed ; wiper motor should first be run to parked position and switched off. " Next, insta¡¡ wiper arms but not blades . " Close hood and fit wiper blades : " Check all electrical harness fittings and sealing grommets for correct reinstallation . Replace al] wire ties cut during removal . CAUTIONThe gaskets and sealing grommets at the ECM compartment cover (passenger side of bulkhead) must be installed correctly to keep moisture out of critica¡ electrical componente.

Fig . 17. Wiper assembly mounting fasteners (arrows) . 11 . Remove wiper assembly support. Refer to Fig . 10 . 12 . Separate harness at bulkhead connector. See Fig . 18 .

Tightening Torques " Wiper shaft nut at cowi . . . . . . . . . . . . . 12 Nm (9 ft-Ib) " Wiper support to wiper assembly or to body . . . . . . . . . . . . . . . . . . . . . . 10 Nm (89 in-lb) - Wiper arm to wiper shaft . . . . . . . . . . 25 Nm (18 ft-Ib)

WINDSHIELD WIPER ASSEMBLY

611-8

WIPERS AND WASHERS

Windshield wiper motor, removing and installing 1 . Disconnect negative (-) cable from battery.

7. Operate motor, then turn off switch . Motor will stop in "park" position . 8. Install wiper arm crank in straight line with linkage. See Fig. 20 .

CA UTION-

" Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡.

NOTE -

When installing wiper crank onto wiper motor, brace crank with a drift pin through the hole on crank into hole on wiper assembly.

" Use tender cover to protect windshield.

2. Remove wiper assembly as described earlier. 3. Remove nut on wiper motor linkage crank and remove linkage crank from motor. See Fig. 19 .

Fig. 20 . Align wiper crank with linkage, as illustrated.

0012538

9. Remainder of installation is reverse of removal. 0012539

Fig. 19 . Wiper linkage crank nut (arrow) and wiper motor mounting bolts (A). 4. Unscrew three motor to assembly mounting bolts and remove motor. Refer to Fig. 19 . 5. Insta¡¡ new motor to wiper assembly. Do not insta¡¡ crank. 6. Connect motor to electrical harness. If necessary, reconnect battery temporarily.

WINDSHIELD WIPER ASSEMBLY

Tightening Torques " Wiper motor to wiper assembly (use new bolts) . . . . . 10 Nm (89 in-lb) " Wiper motor crank to wiper motor (M8 nut) . . . . . . . . . . . . . 27 Nm (20 ft-Ib)

WIPERS AND WASHERS WINDSHIELD CLEANING SYSTEM The windshield cleaning system includes the spray nozzles in the engine hood, the washer fluid pump, and the washer fluid reservoir in the front passenger side of the engine compartment. The windshield spray nozzles can be aimed by using a sewing need1e or a similar diameter stiff piece of wire .

Windshield spray nozzle, removing and installing 1 . Open hood and remove hood insulating pad retaining clips until bottom of nozzle can be fully accessed . See 410 Fenders, Engine Hood . 2. Carefully disconnect hose from nozzle. Disconnect harness connectors for nozzle heater . 3. Push nozzle out of hood . See Fig. 21 .

611-9

Washer fluid reservoir, replacing 1 . Open hood and siphon out washer fluid reservoir. 2. Remove windshield washer pump and hose as described later. 3. Remove windshield washer fluid level sensor as described later. 4. Remove large plastic washer reservoir retainer at fende r. 5. Remove reservoir. 6. Installation is reverse of removal, noting the following: " On installation check that washer fluid hose is not kinked . " Replace hose clamp.

Windshield washer fluid pump, replacing The windshield washer fluid pump ís mounted in the washer fluid reservoir. 1 . Open hood and siphon out washer fluid reservoir. 2. Depress retaining tabs on electrical connector and unplug harness connector from pump. 3. Loosen hose clamp and remove washer fluid line from washer pump . 4. PA pump out of tank. See Fig. 22 .

Fig. 21 . First push nozzle forward then upward from underneath hood . 4. Installation is reverse of removal, noting the following: " Check that colors of harness and nozzle connector match. " Check and adjust nozzles before driving.

Fig. 22. Pull windshield washer pump up to remove (arrow). 5. Installation is reverse of removal. Check pump to tank sealing grommet for damage and correct fit. Replace hose clamp. Check that washer fluid hose is free of kinks.

WINDSHIELD CLEANING SYSTEM

611- 1 0

WIPERS AND WASHERS

Washer fluid leve¡ sensor, replacing (modeis with check control) The washer fluid level sensor is mounted in the fluid reservoir, near the bottom of the container. NOTECheck wire leads at sensor for worn insulation and corrosion. Check electrical contacts in harness connector for corrosion.

1 . Open hood and siphon out washer fluid reservoir. 2. Lift harness connector retaining lever and unplug harness connector to washer fluid level sensor. See Fig. 23 .

3. Pul¡ fluid leve¡ sensor out from rubber grommet. 4. Install new sensor into reservoir. Check sealing grommet for correct fit. Replace if damaged .

WINDSHIELD CLEANING SYSTEM

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

SWITCHES AND ELECTRICAL ACCESSORIES

612-1

612 Switches and Electrical Accessories GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .612-1 INTERIOR SWITCHES . . . . . . . . . . . . . . . . . 612-1

Turn signal switch and wiper switch, replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 612-1 Ignition Switch Assembly . . . . . . . . . . . . . . . . 612-3 Ignition electrical switch, replacing . . . . . . . . . 612-3

Ignition lock cylinder, replacing . . . . . . . . . . . . 612-4 Headlight and Foglight Switch Assembly . . . . 612-5

GENERAL This section covers replacement of interior switches and accessories . When working on electrical switches, always disconnect the negative (-) cable from the battery and insulate the cable end to prevent accidental re-connection . CAUTIONPrior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii. NOTE" Wirfng diagrams can be found in Electrical Wiring Diagrams . " Fuse, relay and electrical component locations can be found in 610 Electrical Component Locations . " Replacement information for the transmission gear position/neutral safety switch is covered in 250 Gearshift Unkage. " Testing and replacement information for the oil oressure switch is covered in 119 Lubrication System .

INTERIOR SWITCHES NOTE To prevent marring interior trim, wrap the tips of screwdrivers and pliers with tape before prying out switches or electrical accessories .

Headlight switch, replacing . . . . . . . . . . . . . . . 612-5 Foglight switch, replacing . . . . . . . . . . . . . . . . . 612-5 Hazard warning switch, replacing . . . . . . . . . .612-5

Power window switch, replacing . . . . . . . . . . . 612-5 Outside mirror switch, replacing . . . . . . . . . . . .612-6

INTERIOR LIGHTS . . . . . . . . . . . . . . . . . . . . . 612-6 Dome light, rear map lights, trunk light, replacing bulbs . . . . . . . . . . . . . . . . . . . . . . .612-7

Turn signal switch and wiper switch, replacing The procedures for removing the turn signal stalk switch and the wiper system stalk switch are similar. 1 . Disconnect negative (-) cable from battery and cover terminal with insulating material . 2 . Remove airbag unit from steering wheel . See 721 Airbag System (SRS) . Store airbag unit in a safe place w¡th pad facing up . WARNING The cars covered by this manual are equipped with a Supplemental Restraint System (SRS) that auto-' matically deploys one or more airbags. Each airbag unit houses an explosive powerful charge . Any work involving the SRS system should only be performed by an authorized BMW dealer. Making repairs without the proper knowledge and special test equipment may cause serious personal injury. See 721 Airbag System (SRS) 3 . With front wheels pointed straight ahead, remove steer¡ng wheel . See 320 Steering and Wheel Alignment . NOTE To helo with reassembly, mark steering wheel and column before disassembly. 4 . Remove trim panel from lower left side of instrument panel . See 513 Interior Trim .

INTERIOR SWITCHES

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

612-2

SWITCHES AND ELECTRICAL ACCESSORIES

5. Remove lower steering column cover from steering column. See Fig. 1 .

0012545

Fig. 3. Depress retaining tabs (arrows) and push holder downwards. Fig. 1. Lower steering column cover retaining screw (arrow).

uu12543

6. Remove stalk switch holder retaining screw. See Fig. 2.

0012556

Fig. 4. Depress upper and lower catches simultaneously and unplug harness connector.

Fig. 2. Stalk switch holder retaining screw (arrow).

0012555

7. Depress retaining tabs to release stalk switch holder. Push stalk switch holder downwards and off steering column . See Fig. 3. 8. Depress catches on stalk switch and release switch from columna See Fig . 4. 9. Cut wíre ties retaining harness to steering column . Disconnect switch electrical connector located at bottom of steering shaft. 10 . Installation is reverse of removal, noting the following:

" Place turn signal indicator in center position before installing . " Ensure that self cancelling cams on turn signal switch are not damaged during installation .

INTERIOR SWITCHES

WARNING -

Once the airbag unit is installed and all other service procedures have been completed, start the engine and check that the SRS warning light goes out. If the warning light stays on, the SRS system will not function as designed. Have the system diagnosed and repaired by an authorized BMW dealer.

Tightening Torques " Steering wheel to steering column spindle (Bolt) . . . . . . . . . . . . . 63 Nm (46 ft-lb)

SWITCHES AND ELECTRICAL ACCESSORIES Ignition Switch ASsembly

612-3

3. Remove screw retaining lower steering column cover and remove cover. Refer to Fig. 1 . ,

The components of the ignition switch assembly are shown in Fig. 5. The ignition electrical switch and the ignition lock cylinder can be removed with the ignition switch assembly attached to the steering column .

4. Clean away colored sealer from ignition switch set screws and remove slotted set screws on both sides of switch . See Fig. 6. 5. Release tabs and remove switch after separating electrical harness connector.

ignition electrical switch, replacing 1 . Disconnect negative (-) cable from battery and cover terminal with insulating material .

6. Installation is reverse of removal, noting the following :

" Before mating ignition electrical switch to ignition lock, check that switch is in correct position relative to ignition lock . " Seal set screws using paint or lacquer.

CAUTION-

Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡.

2. Remove trim panel from lower left side of instrument panel. See 513 Interior Trim .

EWS II ring antenna (Jan . 1995 and later models)

F~"

0012241

Fig. 5. Ignition switch assembly. INTERIOR SWITCHES

612-4

SWITCHES AND ELECTRICAL ACCESSORIES

Fig. 6. Ignition switch set screws (arrows) .

0012555 0011808

Fig. 8. With ignition key in "radio" position, insert stiff wire into lock opening to release cylinder.

Ignition lock cylinder, replacing NOTE-

On cars with EWS 11(production date 1/95 and later), the ring antenna surrounding the ignition switch must be removed. See 515 Central Locking and Anti-theft .

1 . Insert master key finto lock cylinder and turn 60° to "radio" position . See Fig. 7.

Headlight and Foglight Switch Assembly The headlight and foglight switches are retained in the left dashboard insert . This also contains the driver's side face leve¡ air vents. To service either switch, remove insert by removing a single screw. See Fig. 9. NOTE-

Access to electrical hamess connectors behind dash insert may be easier if lower left dash trim and driver side knee bolsterare removed. See 513 Interior Trim .

Fig. 7. Turn ignition switch 60° to "radio" position (arrow).

0011807

2. Insert a thin piece of stiff wire into opening in lock cylinder and pull lock cylinder out. See Fig. 8. NOTE-

On early cars (up to production date 1ol95), turn lock cylinder back 12° to release .

INTERIOR SWITCHES

Fig. 9. Remove retaíning screw to pull out left dash insert (arrow) .

SWITCHES AND ELECTRICAL ACCESSORIES

612-5

Headlight switch, replacing 1 . Remove left side dash insert and disconnect harness connector to headlight switch . See Fig . 10 .

0012560

Fig. 12. Fit groove on headlight switch into switch bezel on dash insert (arrows) . 0012559

Fig. 10 . Removing headlight switch electrical harness connector (arrow).

Foglight switch, replacing 1 . Remove left side dash insert, as described earlier, and remove foglight switch harness connector.

2. PA off headlight switch knob . Wrapping adhesive tape around knob facilitates removal.

2. Slide foglight switch out of dash insert by sqúeezing spring tabs together.

3. Remove nut mounting switch to dash insert . See Fig. 11 .

3. Installation is reverse of removal .

Hazard warning switch, replacing 1 . Unclip shift boot and lift up from shift lever console . Carefully remove insulation pad. See 250 Gearshift Linkage. 2. Working underneath center console, push hazard warning switch up and out of console with your fingers. 3. Disconnect harness connector from switch . 4. Installation is reverse of removal.

Power window switch, replacing Fig. 11 . Headlight switch mounting nut (arrow) .

0012558

1 . Unclip shift boot and lift up from shift lever console. Carefully remove insulation pad. See 250 Gearshift Linkage .

4. Pull switch out from housing.

2. Working underneath center console, push window switch up out of console with your fingers. See Fig. 13 .

5. Installation is reverse of removal . Align new switch to dash insert . See Fig. 12 .

3. Disconnect harness connector from switch . 4. Installation is reverse of removal.

Tightening Torque " Headlight switch retaining nut . . . . . . . 2 Nm (18 in-lb)

INTERIOR SWITCHES

612-6

SWITCHES AND ELECTRICAL ACCESSORIES INTERIOR LIGHTS Dome light, rear map lights, trunk light, replacing bulbs 1 . Pry dome light out from left side . See Fig . 14 .

0012561

Fig . 13 . Removing window switch from console .

Outside mirror switch, replacing 1 . Carefully pry mirror switch from arm rest . See Fig . 14 .

Fig . 15 . Dome light assembly being removed . 2 . Release locking blade and swing back reflector. Spread apart contact blades to replace buib. 3 . Pry rear map light out with small screwdriver, remove reflector and replace bulb . See Fig . 16 .

Fig . 14 . Pry outside mirror switch from door arm rest .

0013168

2 . Disconnect harness connector from switch . 3. Installation is reverse of removal .

Fig . 16 . Rear interior light assembly shown removed .

INTERIOR LIGHTS

0011855

SWITCHES AND ELECTRICAL ACCESSORIES

612-7

4. Use screwdriver to carefully pry off trunk light lens and replace bulb. See Fig. 17 .

Fig. 17 . Trunk light lens being removed.

uulio56

Interior Light Bulb Wattages " Dome light . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 watts " Rear map light . . . . . . . . . . . . . . . . . . . . . . . . . 5 watts " Trunk light . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 watts

INTERIOR LIGHTS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

INSTRUMENTS

620-1

620 Instruments GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620-1 INSTRUMENT CLUSTER . . . . . . . . . . . . . . . 620-1

Instrument cluster, seif-testing . . . . . . . . . . . . 620-1 Instrument cluster, removing and installing . . . 620-1 Instrument cluster bulbs, replacing . . . . . . . . . 620-2

GENERAL This repair group covers removal and installation of the instrument cluster and the Multi-information Display (MID) module. Bulb replacement information for these units is also included here . NOTE -

A quick check of the temperature gauge and its electrical circuit is given in 170 Radiator and Cooling System. Use this procedure to diagnose a faulty temperature gauge

INSTRUMENT CLUSTER When servicing the instrument cluster, always disconnect the negative (-) cable from the battery and insulate the cable end to prevent accidental re-connection .

Instrument cluster, seif-testing Severa¡ different versions of the basic instrument cluster have been fitted in E36 cars . It is possible to perform an instrument cluster test and display system test information . Some of the information displayed by the instrument cluster during seif-testing is used for interna¡ BMW organization purposes, such as matching the correct instrument cluster components during parts replacement . Other functions test the various instrument modules. Self-test is also used to recode the instrument cluster after removal. In later production vehicles (1996 and later) the test results can be downioaded, via the diagnostic plug, by an authorized BMW dealer technician .

Odometer coding plug, replacing . . . . . . . . . . . 620-2 Vehicle speed sender, replacing . . . . . . . . . . . 620-3 MULTI-INFORMATION DISPLAY (MID) . . . 620-4 Multi-Information Display, removing and installing . . . . . . . . . . . . . . . . . 620-4

3. With each subsequent press of the button, a different function is tested . Some functions will activate need1e gauges . 4. Turn off ignition .

Instrument cluster, removing and installing 1 . Disconnect negative (-) cable from battery and cover terminal with insulating material . CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡.

2. Remove airbag unit from steering wheel. See 721 Airbag System (SRS). Store unit in a safe place. WARNING The airbag is an explosive devfce and should be treated with extreme caution. Improper handling of the airbag could cause serious injury or death . Store the airbag with the horn pad facing up . If stored facing down, accidental deployment could propel it vfolently into the air, causing injury.

3. With front wheels pointed straight ahead, remove steering wheel. See 320 Steering and Wheel Alignment. 4. Remove instrument cluster retaining screws . See Fig. 1. 5. Place a towel over steering column . Carefully tilt top of cluster out of dash panel. Unlock and disconnect harness connectors from back of cluster. See Fig. 2.

1 . Turn ignition to "radio" position . 2. Press and hold reset button on trip-odometer until tripodometer display shows numerical codes.

INSTRUMENT CLUSTER

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

620-2

INSTRUMENTS

0012562

Fig. 1 . Instrument cluster retaining screws (arrows) .

Fig . 3. Turn bulb base 45° in direction shown (arrow) .

Fig . 2. Instrument cluster connector locking lever (arrow) .

oo13n6

6 . Installation is reverse of removal, noting the following : " Instrument cluster harness connector locking levers must be in up position before installing connector. " Install airbag to steering wheel as described in 721 Airbag System (SRS) . " Reconnect negative (-) cable to battery last, once al¡ harness connectors have been reconnected . " Recode cluster as described in Instrument cluster, seif-testing .

Instrument cluster bulbs, replacing 1 . Remove instrument cluster as described above . 2 . Remove faulty bulb by turning bulb base 45° in its mount and remove from housing . See Fig . 3 . The back of the instrument cluster and its bulb locations are shown in Fig . 4 .

INSTRUMENT CLUSTER

l 15

1 . Temperature warning 2 . Right turn signal 3 . Instrument lighting 4. Oil pressure warning 5. Highbeam 6 . Battery charging lamp 7 . Left turn signal 8 . Low fuel warning 9 . Airbag warning 10 . Catalytic converter warning 11 . Emergency brake Fig . 4.

v 16 )7

w r v y 18 19 20 21

12 . Brake fluid warning 13 . Brake pad wear warning 14 .ABS warning 15 . Seat belt warning 16 .ASTwarning 17 .Check control 18 .Check engine 19 . LCD lighting 20 . Rear foglight (not used) 21 . Front foglights

Bulb designation chart .

0012563

CAUTIONNote wattage of bulb. Excessive wattage could melt cluster housing. Replace defective bulbs with reptacementbulbs of the same wattage .

Odometer coding plug, replacing The coding plug maintains a record of the vehicle mileage . 1 . Record vehicle mileage . 2 . Remove instrument cluster as described earlier .

INSTRUMENTS

620-3

3. Break open plastic retainer in back of instrument cluster and remove coding plug . See Fig. 5.

1 ILO

0013029 0013180

Fig. 6. Vehicle speed sender harness connector (A) and sender (B).

Fig. 5. Remove coding plug retainer with a screwdriver (arrow). 4. Install coding plug and new retainer. Reinstall instrument cluster.

2. Remove vehicle speed sender retaining screws and remove sender from differential cover.

5. Reset vehicle mileage.

3. On installation, replace O-ring and coat with oil (90W). See Fig . 7.

NOTEConsultan authorized BMW dealer service department about resetting vehicle mileage using the special BMW Service tester.

Vehicle speed sender, replacing The vehicle speed sender supplies an electronic pulsed speed signal to the speedometer. The sender is mounted beneath the rear of the car, on the differential cover plate. NOTEIf the speedometer is malfunctioning, check the vehicle speed sensor hamess connector on the rear differential. Water damage, frayed wires and corrosion of the connectorcontactsareoftenthecause ofspeedometer malfunction.

1 . Locate vehicle speed sender electrical connector at back of differential . Depress retaining levers on connector and remove . See Fig. 6.

0011755

Fig. 7, O-ring correctly installed on vehicle speed sender, 4. Insta¡¡ sender into differential and tighten mounting bolts evenly in stages until the sender is firmly seated . Tightening Torque " Vehicle speed sender to differential cover . . . . . . . . . 6.6-8 .4 Nm (53-74 in-lb)

INSTRUMENT CLUSTER

620- 4

INSTRUMENTS

MULTI-INFORMATION DISPLAY (MID) Severa¡ different versions of the Multi-Information Display, have been installed in E36 cars . The top-of-the-line model is called the Oh-Board Computer . See Fig. 8. Ambient temperature/ciock

111

0012564

Fig. 9. Removing the Multi-Information Display (MID) module .

Check control/clock

Fig. 10 . MID wiring harness release lever (arrows). 0013028

Fig. 8. Different versions of Multi-Information Display (MID) installed in E36 cars .

Multi-Information Display, removing and installing The Multi-Information Display (MID) is illuminated by bulbs. It must be removed to replace the bulbs. Bulb replacement is included in this procedure. 1 . Remove dashboard parcel shelf. Reach under MID module and push outward. See Fig. 9. 2. Slide harness retaining lever forward to release MID from wiring harness. See Fig . 10 . 3. To Rmove a faulty bulb, use a narrow screwdriver to turn bulb base 45° counter clockwíse. See Fig. 11 .

MULTI-INFORMATION DISPLAY (MID)

Fig. 11 . Turn bulb base 45° counterclockwise . 4. Installation is reverse of removal.

0012566

EXTERIOR LIGHTING

630-1

630 Exterior Lighting GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . 630-1

Side Marker Lights . . . . . . . . . . . . . . . . . . . . . . 630-4

FRONT LIGHTING . . . . . . . . . . . . . . . . . . . . . 630-1 Headlight buib, replacing . . . . . . . . . . . . . . . . 630-1 Headlight assembly, removing and installing . . . . . . . . . . . . . . . . 630-2 Foglight assembly, removing and installing . . 630-3 Front turn signal assembly, removing and installing . . . . . . . . . . . . . . . . 630-4

REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . . 630-4 Taillight Bulbs . . . . . . . . . . . . . . . . . . . . . . . . . 630-4 Taillight assembly, removing and installing . . . 630-5 Center Brake Light . . . . . . . . . . . . . . . . . . . . . . 630-5 Center brake light housing, replacing (4-door and coupe models) . . . . . . . . . . . . . .630-5 License plate light, removing and installing . .630-6

GENERAL The headlight and foglight assemblies use halogen bulbs. To ensure the longevity of halogen bulbs, the bulb glass should not be handied. Dirt and skin oíls may cause a bulb to fail prematurely . If necessary wipe bulb using a clean cloth dampened with rubbing alcohol. NOTEUse only original equipment replacement bulbs. Nonoriginal equipment bulbs may cause false failure readings on the check control display (where applicable). WARNING INhen working on electrical systems, remove the fuse protecting the circuit under repair. See 610

Electrical Component Locations.

FRONT LIGHTING Headlight bulb, replacing 1 . Open engine hood .

0012567

Fig. 1 . To release bulb from headlight assembly, rotate socket counterclockwise to disengage retaining tabs (arrows) . Right side bulb is shown in unlocked position . Note that bottom tab A is wider than other two. 4. Installation is reverse of removal. Align tabs on bulb base to cutouts on rear of lens assembly. Secure bulb by rotating clockwise 90°. Bulb Applications " Low beam headlight bulb . . . . . . . . . . . . . . . . . H9006 " High beam headlight bulb . . . . . . . . . . . . . . . . H9005

2. Working in back of headlight assembly, grasp rear of bulb socket (harness connector) and turn counterclockwise 90°. Pull bulb out of headlight assembly. See Fig. 1 . 3. Disconnect harness connector from bulb . CA UTIONDo not touch halogen bubs with your bare hands . If necessary wipe bulb using a clean cloth dampened with rubbing alcohol.

FRONT LIGHTING

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

630-2

EXTERIOR LIGHTING

Headlight assembly, removing and installing

6 . Remove two screws on bottom of assembly. See Fig . 4.

CAUTIONFollowing headlight assembly work headlight beam aim must be adjusted using special equipment. 1 . Left side : Remove air filter housing, air intake duct, and air mass meter. See 100 Engine-General . 2 . Disconnect harness connectors from headlight bulbs . 3 . Remove front turn signal . See Front turn signal assembly, removing and installing later in this repair group . 4 . Remove radiator cover. See Fig . 2 .

Fig . 4 .

0012567a

Headlight bottom retaining screws (arrows) . Screws mount in threaded expanding rivets which act as headlight height adjusters .

7. Remove headlight assembly from front . 8 . On installation, tighten lower screws first while holding expanding rivets with a wrench . There should be a 2 .5 mm gap between bottom of lens and front panel . Use adjusting nut to raise or lower headlight unit . See Fig. 5 .

0012568

5 . Using a wrench, brace adjusting nut at top center of headlight. Remove three screws at top of assembly. See Fig . 3 .

0012681

Fig . 5 .

Measure gap A (2 .5 mm) between bottom of headlight assembly and front panel .

9 . Clearance between hood and headlight cover should be 1 .5 mm . Adjust by turning upper headlight adjustinq nuts, then tighten down center screw. See Fig . 6.

Fig . 3 .

0012569

Brace headlight adjusting nut as shown and remove top screws (arrows) .

FRONT LIGHTING

EXTERIOR LIGHTING

630- 3

1 . Insert a screwdriver in upper air duct inlet of front lower valence and disengage foglight lens catch mechanism. Swing light outward and gently disengage hinged end. See Fig. 8.

0012682

Fig. 6. Measure gap B (1 .5 mm) between front of hood and headlight cover. Note horizontal headlight adjusting nut (1) and retaining screw (2). Fig. 8. Insert screwdriver in upper air duct inlet.

Foglight assembly, removing and installing The following procedure covers foglight lens and foglight buib replacement. Foglight components are shown in Fig. 7.

uu¡¿biu

2. Remove rear protection cap and disengage steel wire foglight bulb clamp. 3. Remove bulb from rear of foglight assembly. Disconnect electrical harness from foglight bulb . CAUTION Do not touch halogen bulbs with your bare hands. If necessary wipe buib using a clean cloth dampened with rubbing alcohol. 4. Installation is reverse of removal. Check electrical connector for corrosion. Spray with contact cleaner, if necessary.

4 1 . Foglight lens release catch 2. Foglight lens rear protective cap 3. Foglight bulb 4. Foglight lens

0012683

Bulb Application (USA Models): " Foglight bulb . . . . . . . . . . . . . . . . . . . . . . . . Hl (55w)

Fig. 7. Foglight assembly (removed).

FRONT LIGHTING

630-4

EXTERIOR LIGHTING Side Marker Lights

Front turn signal assembly, removing and installing The procedure below also includes turn signal bulb replacement. 1 . Working inside engine compartment, use a screwdriver to press turn signal assembly retaining clip away from retaining tab on headlight assembly frame . Push turn signal forward . See Fig. 9.

Side marker lights on later model E36 cars are snapped into the front fenders. To service, carefully pry the assembly out of the fender, then detach the electrical harness connector and bulb socket .

REAR LIGHTING Taillight Bulbs To access taillight bulbs, see Fig . 11 . The location of the rear bulbs are shown in Fig. 12 . Turn bulb socket 1/4 turn to remove .

Fig. 9. Press on clip (arrow) . Light slides straight out.

0012571

2. Depress tabs on bulb socket and remove from turn signal assembly. See Fig . 10 .

Fig. 11 . To remove taillight bulb cover, turn retainer (arrow) 1/a turn counterclockwise .

0012572

Fig. 10 . Depress locking tabs (arrows) to remove bulb and socket from turn signal housing.

Fig. 12 . Taillight bulb identification .

0012574

REAR LIGHTING

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

EXTERIOR LIGHTING

630-5

Taillight assembly, removing and installing 1 . Open trunk lid. Remove cover from rear of taillight. Refer to Fig. 11 . 2. Depress locking tabs on electrical harness convector and disconnect from rear of taillight lens assembly. Remove four taillight assembly retaining nuts . See Fig. 13 .

0012575

Fig. 14 . Turn center brake light socket counterclockwise and remove bulb .

Center brake light housing, replacing (4-door and coupe models) 1 . Remove rear window parcel shelf. See 513 Interior Trim . 0012574

Fig. 13 . Taillight mounting nuts (arrows) and harness connector (A). 3. Installation is reverse of removal.

Center Brake Light

2. Depress tabs on center brake light electrical connector and disconnect . 3. Remove retaining screws and remove socket . 4. Replace bulb .

On convertible models, it is necessary to open trunk lid and remove inner tailgate trim adjacent to license plate light assembly . Then remove the electrical connectors and four center brake light retaining nuts . Push center brake light out. Replace bulbs if necessary. On 4-door and coupe models, open trunk lid. Working directly under center brake light, turn bulb socket counterclockwise 1/4 turn and remove from center brake light assembly . Replace bulb if necessary. See Fig. 14 .

REAR LIGHTING

630-6

EXTERIOR LIGHTING

License plate light, removing and installing 1 . With trunk lid raised, remove lícense plate light trim panel screws. See Fig. 15 .

Fig. 16 . Insert screwdriver (arrow).

0012577

NOTE Inspect bulb contact springs for damage and corrosión. Reptace socket assembly if necessary. 0012576

Fig. 15. Remove screws (arrows) and remove license plate light trim panel . 2. Using a flat tipped screw driver, pry gently on right side of license plate light assembly. See Fig. 16 . 3. Lift license plate light assembly from sheet metal. Release harness connector locking tabs and separate harness from license plate light electrical connector.

REAR LIGHTING

4 . Installatíon is reverse of removal .

HEATING AND AIR CONDITIONING

640-1

640 Heating and Air Conditioning GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640-1 HEATER AND CONTROLS . . . . . . . . . . . . .640-1 Blower motor, removing and installing . . . . . . 640-1 Blower motor resistor pack, replacing . . . . . . 640-3 Heater valve, replacing . . . . . . . . . . . . . . . . . . 640-3 Heater box, removing and installing . . . . . . . . 640-4 Heater core, replacing . . . . . . . : . . . . . . . . . . . 640-6 Heater core temperature sensor, replacing . . 640-7 Heater and A/C Control Head . . . . . . . . . . . . . 640-7 Heater and A/C control head, removing and installing (rotary-knob) . . . . . . . . . . . . . 640-7 Heater and A/C control head, removing and installing (digital-display) . . . . . . . . . . . . 640-8 Heater and A/C control module, removing and installing (rotary-knob) . . . . . . . . . . . . . 640-8 Heater and A/C control module, removing and installing (digital-display) . . . . . . . . . . . . 640-8 Sensor fan for interior temperature, replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 640-9 Heater and A/C Air Distribution Motors . . . . . . 640-9

Heater and A/C air distribution motor, replacing (rotary-knob) . . . . . . . . . . . . . . . . 640-10 Rear Window Defogger . . . . . . . . . . . . . . . . 640-10 Rear Window Blower (convertible models) . .640-10 AIR CONDITIONING . . . . . . . . . . . . . . . . . . 640-11 A/C System Warnings and Cautions . . . . . . :640-11 A/C compressor, replacing . . : : . : : . . . . . . . .640-12 A/C Compressor Clutch . . . . . . . : . . . . . . . . . 640-13 A/C condenser, replacing . . . . . . . . . . . . . . . . 640-14 A/C receiver/drier, replacing . . . . . . . . . . . . . 640-15 A/C expansion valve, removing and installing . . . . . . . . . . . . . . . . 640-16 A/C evaporator, removing and installing . . . . 640-17 A/C evaporator temperature sensor, replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 640-17 A/C microfilter, replacing . . . . . . . . . . . . . . . . 640-18 TABLES a. Blower Motor Test Values . . . . . . . . . . . . . . . . . . . . 640-3 b. Heater Core Temperature Sensor Test Values . . . .640-7 c. Evaporative Temperature Sensor Test Values . . . 640-17 d . A/C System Fluid Capacities (total) . . . . . . . . . . . . 640-18

GENERAL E36 cars are equipped with integrated automatic heating and air conditioning systems . Many of the procedures given in this repair group require that the A/C refrigerant charge be evacuated using specialized equipment . See A/C System Warnings and Cautions later in this repair group. HEATER AND CONTROLS

Blower motor, removing and installing NOTE-

On 6-cylinder cars, the plastic top engine cover and fuel rail covermustbe removed. The fuel injectorhamess retaining screws must be removed and the harness set aside. The engine control module (ECM) cover must be removed, the control unit connectors unplugged and the harness pulled out of the way. See 130 Fuel Injection .

1 . Disconnect negative (-) cable from battery.

0012527

Fig . 1. Detach grille retaining clips (arrows) and pull grille upward and out of rubber gasket . CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

2. Open hood. Unclip engine bulkhead plenum grille at base of windshíeld and remove grille. See Fig . 1 . HEATER AND CONTROLS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

640-2

HEATING AND AIR CONDITIONING

3. Remove wiring harness retaining clip at bulkhead . Remove screws retaining wiring harness cover and pull cover forward. See Fig. 2.

Fig. 4. Remove screw at A and pull air plenum upward .

0012534

0012529

Fig. 2. Ming harness cover screws at base of windshield (arrows) . 4. On passenger side, push aside wiring harness and remove two screws retaining plenum housing. See Fig. 3.

0012636

Fig. 5. Blower motor housing clips (A); control cable (B); and center retainer (C).

Fig. 3. Ríght side plenum retaining screws (arrows) .

VU1L535

5. On driver side, push aside wiring harness and remove screw retaining plenum . Pull plenum up and remove from engine bay. See Fig. 4. 6. Unclip blower motor housing cover, disconnect control cable, and turn center retainer 1/4 turn to remove cover. See Fig. 5. 7. Disconnect electrical connectors from blower motor. 8. Remove left upper section of blower housing by detaching spring clips at edge of housing. See Fig. 6.

HEATER AND CONTROLS

Fig. 6. Spring clips (arrows) on driver side of blower housing.

i [u6,

HEATING AND AIR CONDITIONING

640- 3

9. Release blower motor retaining strap and remove blower motor and fans from cowl opening.

NOTE-

Twist and rotate blower motor assembly to facilítate removal from opening . If the blower motor is to be reinstafled, use care not to damage fan wheels during removal. ff the blower motor fs to be replaced, cut off fan wheels at center to aid in removal.

10 . Installation is reverse of removal. When installing a replacement blower motor, instan motor into cowl area before installing fan wheels . Blower motor test specifications are listed in Table a.

NOTE -

On replacement blower motors from BMW, the fan wheels come unattached to aid in installation. Locate arrow on blower motor and instan fan wheels at this position. Be sure color coolng matches. Retain fan wheels using the new clips. See an authorized BMW parts department for the latest parts information.

Table a. Blower Motor Test Values Testing voltage

13 VDC

Operating voltage

9-15 VDC

Max. current consumption (approx.)

12 amps

Maximum speed

3,600-4,000 rpm

Axial play (max . allowable)

1 .0 mm (0 .04 in .)

uuiGO4I

Fig. 7. Blower fan resistor pack (black arrow) and resistor pack receptacle (white arrow) below left side of dash .

WARNING -

Allow the cooling system to cool before opening or draining the cooling system .

2. Disconnect hoses and harness connector at heater valve . See Fig. 8.

Blower motor resistor pack, replacing The blower resistor pack is clipped into the upper left side of the heater box. 1 . Remove lower left dash trim panel. See 513 Interior Trim . 2. Working under left (driver's) side of dash, unclip and pulí out resistor pack from side of heater box. Remove harness connector from resistor pack . See Fig. 7. 3. Installation is reverse of removal.

Heater valve, replacing The two-way heater valve is located in the rear of the engine compartment on the driver side . The solenoid operated valves control the coolant flow through the dual-chamber heater core . 1 . Drain engine coolant. See 170 Radiator and Cooling System .

001[ó38b

Fig. S. Hoses (A) and harness connector (B) at heater valve.

3. Carefully pull heater valve out of rubber mounting and pull up and out of engine compartment. 4. Installation is reverse of removal. Use new hose clamps . Inspect hoses and replace as necessary.

HEATER AND CONTROLS

640-4

HEATING AND AIR CONDITIONING

Heater box, removing and installing The heater box, located underneath the center of the dashboard, houses the heater core, the A/C evaporator, and associated sensors and actuators. Removal of the heater box requires that the A/C refrigerant be discharged . CAUTION-

" Removing the heater box requires evacuating the AIC system. DO NOT attempt this procedure without proper tools and training . " Any person who services a motor vehicle air conditioner must, by law, be properly trained and certified, and use approved refrigerant recycling equipment. Technicians must complete an EPAapproved recycling course to be certified

UU12639

1 . Drain engine coolant. See 170 Radiator and Cooling System . 2. Remove complete dashboard. See 513 Interior Trim . 3. Remove blower motor as described earlier.

Fig. 10. Heater core mounting nuts at left side of bulkhead (arrow) . wiper assembly shown removed for clarity.

6. Cut wire tie holding wire harness to heater box and disconnect cable harness connector from heater box. See Fig. 11 .

4. Remove nut retaining water hose flange to rear bulkhead . I'ush flange to one side . See Fig. 9.

0012647

Fig. 11 . Harness connectors (A) and cable tie (B) at heater box, under driver side dash . Fig. 9. Nut retaining coolant hose flange at bulkhead (arrow).

7. Following manufacturer's instructions, connect approved refrigerant recovery/recycling/recharging unit to A/C system and discharge system .

NOTEClear any remaining coolant from the heater core by blowing compressed air finto the coolant feed hose.

8. Unbolt A/C refrigerant lines flange from engine bay bulkhead . See Fig. 12 .

0012638b

5. Remove nuts from heater box retaining bracket on engine bulkhead left side . See Fig. 10 . Repeat procedure for right side nuts. HEATER AND CONTROLS

9. On models with rotary-knob A/C control head : Disconnect wiring harness connectors to A/C control module in center console and remove module . See Fig. 13 .

HEATING AND AIR CONDITIONING

Fig. 12 . Mounting bolt for A/C refrigerant line flange (arrow).

640-5

0012644

Fig. 14 . Heating and ventilation ducts on left side of heater box (arrows) . Right side ducts are similar.

001Suu7

Fig. 13. A/C control module (A) behind center console. Arrows point to electrical harness connectors to be disconnected . 10 . Unclip and remove heating and ventilation ducts on sides of heater box. See Fig. 14 . 11 . Remove heater box retaining bracket on center tunnel and remove heater box. See Fig. 15 . 12 . Installation is reverse of removal . Evacuate and recharge A/C system using specialized equipment. Fill and bleed cooling system . See 170 Radiator and Cooling System .

0012645

Fig. 15. Heater box retaining bracket in center console (arrow).

Tightening Torques " A/C refrigerant lines flange to bulkhead . . . . . . . . . . . . . . . . . . . . 3.5 Nm (31 in-lb) " Water hose flange to bulkhead (M6 nut) . . . . . . . . . . . . . . . . . . . . . . 3.5 Nm (31 in-lb) " Heater box retaining bracket to tunnel . . . . . . . . . . . . . . . . . . . . . . 4.5 Nm (40 in-lb)

CAUTION -

Replace heater and AIC flange O-rings and tighten fasteners to specified torques.

HEATER AND CONTROLS

640-6

HEATING AND AIR CONDITIONING

Heater core, replacing

1 . Drain engíne coolant. See 170 Radiator and Cooling System . WARNING Allow the cooling system to cool before opening or drainíng the cooling system.

2. Remove center console. See 513 Interior Trim . 3. Remove Multi-Information Display (MID) module . See 620 Instruments. 4. Remove lower dash panel and knee bolster on driver side. See 513 Interior Trim . 5. Working under driver side of dash, remove coolant flange from heater core . See Fig . 16 .

0012651

Fig. 16 . Bolts at 3-way coolant flange under driver's side of dash (arrows).

Fig. 17 . Wire harness retaining clips and wire ties at heater box cover (arrows) .

0012662

Fig. 18. Screws retaining front heater box cover (shown removed) to heater box (arrows) .

NOTEResidual coolant in heater core will spill. Protect the carpet.

6. Working at front of driveshaft tunnel, unclip wire harnesses and move to one side in front of heater box. See Fig. 17. 7. Remove heater core temperature sensors as described later in this repair group. 8. Remove front heater box cover. See Fig. 18. 9. On right side of heater box, unclip heater air duct actuating lever. Remove cross-rod (with flaps) from front of heater core . See Fig . 19 .

0012661

Fig. 19. Pry heater flap actuating lever in direction A. Pull off air flap cross-rod in direction B.

HEATER AND CONTROLS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

HEATING AND AIR CONDITIONING

640-7

10 . Pul¡ heater core up and backward, away from heater box. If necessary, remove left and right reinforcing bracket bolts. See Fig. 20 .

0012648

Fig. 21 . Remove heater core temperature sensors in direction shown (arrow). 0012660

Fig. 20 . PA heater core up and toward back of car. Lower mounting bolts for steering column brace and glove compartment support frame may have to be removed (arrows) . 11 . Installation is reverse of removal. Fill and bleed cooling system . See 170 Radiator and Cooling System . CAUTION-

Replace coolant flange O-rings and tighten fasteners to specified torques .

Tightening Torques " Coolant flange to heater core . . . . . . . 3 Nm (27 in-lb)

Heater core temperature sensor, replacing The automatic heating and air conditioning system uses severa¡ sensors to control interior air temperature . Use the following procedure and the data in Table b to pinpoint problems with the heater core sensors. 1 . Remove center console. See 513 Interior trim . 2. Remove Multi-Information Display (MID) module . See 6201nstruments .

Table b. Heater Core Temperature Sensor Test Values Test temperature

Resistance

4°F (-20°C)

84 .39 - 109.61 k ohms

14 °F (-10°C)

48 .58 - 62 .09 k ohms

32°F (0°C)

28 .89 - 36 .40 k ohms

68°F (20°C)

11 .13 - 13 .83 k ohms

140°F (60°C)

2.19 - 2.78 k ohms

212°F (100°C)

0.58 - 0 .77 k ohms

Heater and A/C Control Head Two types of heater and aír conditioning control heads viere installed in E36 cars . Early models have control heads with four rotary knobs and a separate control module . A flexible shaft, clipped to the right side of the control head, controls the heater flaps. Later model E36 cars, starting in approximately mid-1995, have digital display control heads with buttons. The A/C control module is integrated with the digital control head .

Heater and A/C control head, removing and installing (rotary-knob)

3. Pul¡ temperature sensors from heater box and disconnect harness connectors. See Fig. 21 .

1 . Remove Multi-Information Display (MID) module from center of dash . See 620 Instruments.

4. Installation is reverse of removal.

2. Pul¡ off outer rotary knobs from A/C control head . Remove two screws on knob bezels . Remove control panel face plate by prying it off control head gently. See Fig. 22 . 3. Carefully push control head back into dash and downward through MID opening. See Fig. 23 .

HEATER AND CONTROLS

640-8

HEATING AND AIR CONDITIONING Heater and A/C control head, removing and installing (digital-display) 1 . Remove Multi-Information Display (MID) module from center of dash . See 620 Instruments . 2 . Reach into dash through MID opening and push A/C control head outwards. 3 . Disconnect harness connector and remove control head . 4 . Installation is reverse of removal

0012649

Fig. 22. A/C control head faceplate screws on rotary knob version (arrows) . Once screws are removed, faceplate must be unclipped from control head .

Heater and A/C control module, removing and installing (rotary-knob) 1 . Remove Multi-Information Display (MID) module from center of dash . See 620 Instruments . 2 . Remove center console . See 513 Interior Trim . 3 . Disconnect wiring harness connectors to A/C control module in center console and remove module . See Fig . 24.

Fig . 23 . Push control panel out of center console .

0012650 0013007

4 . Remove harness connectors . Unfasten heater duct control flex-shaft on right side of control head by squeezing retaining tab . PA shaft out of coupling in control head and remove head . 5 . Installation is reverse of removal .

Fig. 24 . A/C control module (A) in center console . Arrows point to electrical harness connectors at A/C module.

Heater and A/C control module, removing and installing (digital-display) The A/C control module for cars with the digital display is mounted on the back of the control head . See Fig . 25 . 1 . Remove control head as described earlier and place on an anti-static mat .

HEATER AND CONTROLS

HEATING AND AIR CONDITIONING

640-9

Heater and A/C Air Distribution Motors The recirculation, fresh air and other vent-duct flaps are controlled electrically via a series of air distribution actuating motors . Cars with the rotary-knob control head use three electromechanical motors, each held in place via a small plastic clip . See Fig. 27. Sensor fan

Right side of heater box l

Fig. 25 . Digital display A/C control head components . 2. Unscrew left and right screws retaining control head to control module . Press retaining clips and release front plate from control head . Remove A/C control module from control head housing.

Sensor fan for interior temperature, repiacing A small electric fan, installed in the A/C control head, draws cabin air past the climate control temperature sensor. 1 . Remove A/C control head as described earlier. 2. Rotary-knob control head : Disconnect electrical connector from top of control head housing. Pry open plastic housing and remove sensor fan . See Fig. 26 .

Fig. 27. Location of early production air distribution motors (arrows) .

0013181

Later systems (with the digital display control head) use five distribution motors, four of which are digítally controlled . See Fig. 28 .

Fig. 26. Sensor fan (A) and harness (B) in back of A/C control head (rotary-knob control head shown) . 3. Digital display models : Disconnect electrical harness connector from control head housing. Remove screws holding sensor fan to bottom of control module and remove . Refer to Fig. 25 . 4. Installation is reverse of removal.

HEATER AND CONTROLS

640-10

HEATING AND AIR CONDITIONING i

Radio

Antenna Left side

I d

Rear

1 . Rear vents 2 . Fresh air 3 . Face-level vents 4 . Recirculation 5 . Footwell vents

. ,

si,-

0013017

Fig . 28. Location of late production air distribution motors in heater box (shown in rear, side and top views) .

Heater and A/C air distribution motor, replacing (rotary-knob)

Suppressor filter 0013005

Fig . 30 . Wiring diagram of rear window defogger and radio antenna .

1 . To access left side motors (dash vent mixing or recirculation flap), remove lower dash panel and knee bolster on driver side . See 513 Interior Trim .

Rear Window Blower (Convertible Models)

2 . To access right side motor (fresh air flap), remove glove compartment . See 513 Interior Trim .

A blower fan, fitted into the rear seat back, defogs the rear window . It will only operate with the engine nunning and the top raised . A microswitch behind the rear seats provides the signal that the top is raised .

3. Each motor can be removed after its electrical wiring harness connector has been removed. Squeeze plastic clip to release motor. See Fig . 29 .

To access the blower fan motor, it is necessary to remove four screws from the center seat back . Remove the wiring harness connector and motor mounting boits, then remove motor by pulling it down and forward . See Fig . 31 .

0011877

Fig . 29. A/C air distribution motor plastic retaíning clip (arrow) . Release clip and tilt motor out of housing .

Rear Window Defogger The electric rear window defogger is integrated with the radio antenna . See Fig . 30 . The rear window defogger switch is integrated with the heating and A/C control head .

HEATER AND CONTROLS

0013014

Fig . 31 . Rear window blower in center of rear seat back (arrow) .

HEATING AND AIR CONDITIONING To access the rear window blower relay, remove the glove compariment . See Fig . 32 .

640-1 1

WARNING "Keep refrigerant awayfrom open llames . Poisonous gas will be producedifit bums. Do notsmoke near refrigerant gases for the same reason. " The AIC system is filled with refrigerant gas which is under pressure. Pressurized refrigerant in the presence ofoxygen may form a combustible mixture . Never introduce compressed air finto any refrigerant container (full or empty), capped off AIC component, or piece of service equipment. " Refrígerant gases are heavier than air, displace oxygen and may cause suffocation in areas of poor círculation, for example under a car. Switch on exhaustlventilation systems when working on the refrigerant system . "State and local governments mayhave additional requirements regarding air conditioning servicing . Always comply with state and local laws.

0013015

Fig . 32. Rear window blower relay located in front of glove compartment (arrow) .

AIR CONDITIONING This section covers removal and installation of air conditioning refrigerant components. A/C testing and diagnosis, refrigerant discharge, evacuatíon and recharge are not covered here. The subassemblies and lines of the air conditioner are filled with either refrigerant R12 (1992 cars) or R-134a (1993 and later cars) . The major components of the A/C system are shown in Fig . 33.

A/C System Warnings and Cautions WARNING " Always be careful that refrigerant does not come in contact with your skin. Always wearhand and eye protection (gloves and goggles) when working around the AIC system. If refrigerant does come in contact with your skin or eyes : -Do not rub skin oreyes; -Immediately flush skin or eyes with cool water for 15 minutes ; -Rush to a doctor or hospital; -Do not attempt to treatyourself. " Workin a wefl ventilated area. Avoid breathing refrigerant vapors . Exposure may irrítate eyes, nose, and throat. Switch on exhaustlventilation systems when working on the refrigerant system.

"Electric welding near refrigerant hoses causes R134a to decompose. Discharge system before welding. CA UTION-As of January 1, 1992, any person who services a motor vehicle air conditioner must, by law, be properly trained and certified, and use approved refrigerant recycling equipment. Technicians must complete an EPA-approved recycling course to be certified. " It is recommended thatal¡system refrigerant AIC refrigerant beleft to an authorized BMW dealer or other qualified AIC service facility. " Do not top off a partially charged refrigerant system. Discharge system, evacuate and then recharge system . " R-134a and R-12 refrigerants and refrigerant oils and system components, including hoses and sealing O-rings, are NOT compatible. Component damage andlor system contamination will result. " The mixture of refrigerant oil (PAG oil) and refrigerant R- 134a attacks some metals and alloys (for example, copper) and breaks down certain hose materials . Use only hoses and lines that are identified with agreen mark (stripe) orthe lettering R134a". " Immediately plug open connections on AIC components to prevent dirt and moisture contamination. " Do not steam clean condensers or evaporators. Use only cold water or compressed air.

" Do not expose any component ofthe AIC system to high temperatures (Above 80°Cl176°F) or open flames. Excessive heat will cause a pressure increase which could burst the system. AIR CONDITIONING

640-12

HEATING AND AIR CONDITIONING

A/C Compressor, replacing 1 . Following manufacturer's instructions, connect an approved refrigerant recovery/recycling/recharging unit to A/C system and discharge system .

4. On 4-cylinder engines: Loosen A/C belt tensioner bolt under trim cap, then remove belt from A/C compressor. See Fig. 35 .

WARNING Do not discharge%harge the AIC system without proper equipment and training. Damage to the vehicle and personal injury may result.

2. Remove splash shield from under engine . 3. Mark A/C drive belt with direction of rotation . Remove A/C belt tensioner trim cap. See Fig. 34.

~=1

A/C compressor

0013019

Fig. 35 . 4-cylinder engines: Loosen retaining bolt A on tensionerto release drive-belt tension. To increase tension, rotate pulley in direction of arrow, then tighten bolt A. 5. On 6-cylinder engines: Release tension on A/C belt by turning tensioner pulley clockwíse (against spring tension). See Fig. 36 . 0011988

Fig. 34 . To access tensioner retaining bolt, remove trim cap from drive-belt tensioner.

Fig. 33. A/C components . Arrows indicate direction of refrigerant flow. AIR CONDITIONING

NOTE Detailed instructions for drive-belt removal and installation can be found in 020 Maintenance Program.

HEATING AND AIR CONDITIONING

640- 1 3

Fig . 38 . A/C compressor mounting boits (arrows) . 9 . Installation is reverse of removal . Fig . 36. 6-cylinder engine belt diagram : To remove A/C belt, lever tensioner (A) in clockwise direction using long-handled wrench or breaker-bar.

CAUTION " Always replace O-rings when reconnecting refrigerant fines.

6 . Disconnect electrical harness connector from compressor.

" When installlng a new compressor always replace receiverldrier unit.

7 . Remove A/C pressure hose and suction hose flange bolts from compressor. Plug hoses immediately See Fig . 37 .

10 . Before recharging, evacuate system for at least 30 min . Recharge system following equipment manufacturer's instructions . See Table d . A/C System Refrigerant Capacities .

Tightening Torques " A/C compressor to engine block . . . . 22 Nm (17 ft-Ib) " A/C line flange to A/C compressor 5/8 in . fine . . . . . . . . . . . . . . . . . . . . . . 20 Nm (15 ft-Ib) 3/4 in . fine . . . . . . . . . . . . . . . . . . . . . . 39 Nm (29 ft-Ib) 7/8 in . fine . . . . . . . . . . . . . . . . . . . . 42 Nm (31 ft-Ib) 11/16 in . fine . . . . . . . . . . . . . . . . . . . . 48 Nm (35 ft-Ib)

A/C Compressor Clutch 0011879

Fig . 37. A/C compressor pressure hose (A) and suction hose (B) . (6cylinder engine shown . 4-cylinder engine is similar.) 8 . Remove compressor mounting boits . See Fig . 38 . Remove compressor by pulling downward from underneath car.

The compressor clutch can be replaced without disturbing the sealed refrigerant system, although clearances in the sixcylinder cars may be very tight . Detach the compressor from the compressor bracket to gain extra clearance . Typical A/C compressor and clutch is shown in Fig . 39 . Remove drive plate and pulley to access clutch magnetic winding . See Fig . 40 .

AIR CONDITIONING

640-14

HEATING AND AIR CONDITIONING Tightening Torque " Compressor clutch bolt to compressor shaft . . . . . . . . . . . . . . 20 Nm (15 ft-Ib)

A/C condenser, replacing 1 . Following manufacturer's instructions, connect an approved refrigerant recovery/recycling/recharging unit to A/C system and discharge system . WARNING Do not dischargelcharge the AIC system without proper equipment and training. Damage to the vehicle and personal injury may result. 2 . Remove front bumper and radiator grilles . See 510 Exterior Trim, Bumpers . 3 . Remove auxiliary electric radiator fan . See 170 Cooling System .

7 1 . Clutch plate retaining bolt 2 . Clutch plate 3 . Pulley retaining circlip 4 . Clutch bearing

00871208

4 . Detach A/C lines from lower right corner of condenser . Plug lines immediately. See Fig . 41 .

5 . A/C compressor pulley 6 . Clutch retaining circlip 7 . Clutch (magnetic winding) 8 . Compressor

Fig. 39. A/C compressor and clutch components .

Fig. 41 . A/C flange bolts at condenser (arrows) . 5 . Remove condenser mounting bolts from front radiator support . See Fig . 42 . 6 . Lift up condenser to disengage from lower mounts and remove from below . 00870082

Fig . 40 . A/C compressor drive plate can be held stationary with strap tool to allow removal of retaining bolt . NOTEBMWs are equipped with compressors from various manufacturers . Special tools may be required to remove driveplate or pulley.

AIR CONDITIONING

7 . Installation is reverse of removal . CA UTION" Always replace O-rings when reconnecting refrigerant fines. " When installing a new condenser always replace receiverldrier unit.

HEATING AND AIR CONDITIONING

Fig. 42 . Upper A/C condenser mounting bolts (arrows) .

640-15

0013182

8. Before recharging, evacuate system for at least 30 min. Recharge system following equipment manufacturer's instructions. See Table d. A/C System Refrigerant Capacities .

0012669

Fig . 43. A/ C receiver/drier electrical harness connectors (A), pressure line retaining bolts (B), and mounting bolts (C) .

A/C receiver/drier, replacing The A/C receiver/drier is mounted in the front right cornee of the engine compartment behind the headlight assembly . CAUTIONThe receiver/drier must be replaced when -There is dirt in the AIC system -The compressor has seized or has been replaced for any reason -The condenser or evaporator are replaced for any reason -The AIC system is leaking and there is no more refrigerant -The AIC system was open for 24 hours or more.

0012668

Fig. 44 . Passenger side splash shield retaining screws (arrows) .

1 . Following manufacturer's instructions, connect an approved refrigerant recovery/recycling/recharging unit to A/C system and discharge system .

8. Push receiver/drier down and remove from underneath car. Make sure that receiver/drier is clear of any electrical harnesses.

2. Remove right headlight assembly. See 630 Exterior Lighting .

9. Installation is reverse of removal.

3. Disconnect A/C electrical harness connectors . See Fig. 43 . 4. Remove refrigerant pressure lines from receiver/drier. Plug lines immediately. 5. Remove receiver/drier mounting bolts.

CAUTIONAlways replace O-rings when reconnecting refrigerant lines.

10 . Before recharging, evacuate system for at least 30 min. Recharge system following equipment manufacturer's instructions. See Table d. A/C System Refrigerant Capacities .

6. Remove underbody splash shield on passenger side . See Fig. 44 . 7. Remove passenger side brake cooling duct . Disconnect outside temperature sensor harness, if applicable .

AIR CONDITIONING

640-16

HEATING AND AIR CONDITIONING

A/C expansion valve, removing and installing

6. Remove A/C refrigerant line fiange bolt(s) from expansion valve. Plug lines immediately. See Fig. 47 .

1 . Following manufacturers instructions, connect an approved refrigerant recovery/recycling/recharging unit to A/C system and discharge system . WARNING Do not discharge%harge the WC system without properequipmentand training. Damage to the vehicle and personal injury may result.

NOTE If necessary, remove air plenum grille from rear of engine compartment as described earlier in Blower motor, removing and installing. Remove wiring hamess cover screws and then remove right side plenum screws. Reaching finto the plenum chamber, remove AIC fine flange bolt to allow expansion valve room for removal.

2. Remove glove compartment and glove compartment support frame. See 513 Interior Trim . 3. Remove right side footwell vents. 4. Remove right side control module carrier screws and tilt carrier down . See Fig . 46 .

0011667

Fig. 47. Refrigerant line fiange mounting bolt at expansion valve (arrow). Fig. 45 . Control module carrier retaining screws (arrows) .

0012666

7. Remove screws from top of expansion valve and remove expansion valve from evaporator. See Fig. 48 .

5. Remove expansion valve cover. See Fig. 46 .

Fig. 46. Four screws retain expansion valve cover (arrows) .

0012663

Fig. 48 . Expansion valve mounting screws (A).

AIR CONDITIONING

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

HEATING AND AIR CONDITIONING

640-17

A/C evaporator temperature sensor, replacing

8. Installation is reverse of removal. CAUTION -

The evaporator temperature sensor is mounted in the left (driver) side of the heater box behind the center console.

Always replace O-rings when reconnecting refrigerant fines.

9. Before recharging, evacuate system for at least 30 min. Recharge system following equipment manufacturer's instructions . See Table d. A/C System Refrigerant Capacities .

A/C evaporator, removing and installing

1 . Remove lower dash panel and knee boister on driver side . See 513 Interior Trim . 2. Remove left footwell ventilation duct by removing retaining rivet in bottom of duct. Pull it down and away from heater box. See Fig. 50.

1 . Following manufacturer's instructions, connect an approved refrigerant recovery/recycling/recharging unit to A/C system and discharge system . 2. Remove complete heater box as described earlier. 3. Remove expansion valve as described earlier. 4. Unfasten evaporator sensor electrical harness connector and puli out sensor from ieft side of heater box. See Fig . 50.

Fig. 50. Left footwell ventilatíon duct (arrow).

0o1300ba

3. Disconnect sensor electrical connector from heater box. Pull sensor straight out of heater box. Refer to Fig. 49 .

ou12b46

Fig. 49. Pull out evaporator sensor from housing in direction of arrow. 5. Remove rear heater box cover. 6. Remove clips retaining lower evaporator housing cover. Tilt out heater core, then pull evaporator out of housing. 7. Installation is reverse of removal. CAUTION -

Always reptace O-rings when reconnecting refrtgerant fines.

8. Before recharging, evacuate system for at least 30 min. Recharge system following equipment manufacturer's instructions. See Table d. A/C System Refrigerant Capacities .

4. Installation is reverse of removal. Table c. lists evaporator temperature sensor test values .

Table c. Evaporator Temperature Sensor Test Values Test temp .

Resistance

23°F (-5°C)

11 .4 -11 .9 k ohms

32°F (0°C)

8.8 - 9.2 k ohms

41 °F (5°C)

6.8 - 7.2 k ohms

50°F (10°C)

5.3-5.6 k ohms

59 °F (15°C)

4.2 -4.5 k ohms

68°F (20°C)

3.3 - 3.6 k ohms

77°F (25°C)

2.6-2 .9 k ohms

86°F (30°C)

2.1 - 2.3 k ohms

95°F (35°C)

1 .7 -1 .9 k ohms AIR CONDITIONING

640-18

HEATING AND AIR CONDITIONING

A/C microfilter, replacing

1 . Remove glove compartment. See 513 Interior Trim . 2. Remove right footwell ventilation duct . See Fig. 51 .

Fig. 53 . A/C microfilter cover release knob (arrow) on passenger side of heater box.

Table d. A/C System Fluid Capacities (total) Fluid 0012664

Fig. 51 . Unfasten retaining rivets from right ventilation duct (arrows) .

3. Remove rightside control module carrier screws and tilt carrier down . See Fig. 52 .

Fig. 52 . Control module carrier retaining screws (arrows) .

0012666

4. Rotate A/C microfilter housing release knob about 45° counterclockwise and remove filter housing cover. See Fig. 53 . 5. Remove microfilter while moving module harnesses out of the way. 6. Installation is reverse of removal.

AIR CONDITIONING

I Quantity

R-12 refrigerant

1200g t 25 g (2 .65 Ibsa 0.05 lbs.)

R-134a refrigerant

1000 g ± 25 g (2 .20 Ibs.t 0.05 lbs.)

PAG oil SP-10 (R12 system)

1200 ml f 20 ml (6.8 oz . ± 0.7 oz .)

Refrigerant oil (R1 34a system)

I Seiko Seiki 150m1

Nippondeso 120mi

RADIO

650-1

650 Radio GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650-1 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 650-1 RADIO AND SPEAKER SERVICE . . . . . . . 650-2 Radio, removing and installing . . . . . . . . . . . . 650-2 Left footwell speaker, removing and installing . . . . . . . . . . . . . . . . 650-3 Right footwell speaker, removing and installing . . . . . . . . . . . . . . . . 650-4

Rear speaker, removing and installing . . . . . .650-5 Door panel speaker, removing and installing . . . . . . . . . . . . . . . . .650-5 Radio connector . . . . . . . . . . . . . . . . . . . . . . . . 650-6 TABLE a . Radio Connector Terminal Designation . . . . . . . . . . 650-6

GENERAL

AUDIO SYSTEM

This section covers the BMW factory-installed sound system, including radio and speaker removal, radio connectors and terminal designations .

The BMW E36 is equipped with a three band radio/cassette player unit mounted in the middle of the center console . In ad dítion to AM and FM bands, the radio will receive broadcasts from the National Weather Service .

The antenna is incorporated into the rear window defogger .

The cassette deck is equipped with the Do1byTM C noise reduction system, for improved tape performance with reduced background tape noise . A 6-speaker audio system was standard in the early years of the model line . Many additional features have been installed as optional or standard equipment during the vehicle production run . " A 200-watt power amplifier with custom-contoured equalization and ten speaker output . See Fig . 1 . " A multi-disc compact disc changer, for which the vehicle and the radio are prewired . See Fig . 2 .

Fig . 1 .

Radio amplifier (premium package) in luggage compartment behind left panel . Fig . 2 .

Optional multi-disc compact disc changer and disc cartridge .

AUDIO SYSTEM

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

650-2

RADIO

" A 320-watt Harmon-Kardon ten speaker system, including a separate high power multi-channel audio amplifier and two sub-woofers . In this system, the bass and volume outputs from the selected audio source automatically compensate for vehicle speed, making constant volume adjustments unnecessary. An additional feature of this sound system is the ability to switch from normal left-right stereo into Spatial Enhancement Mode, which produces a fuller, rounder sound. See Fig. 3. The E36 radio is also equipped with a built-in anti-theft system. lf power is removed from the radio circuitry by removing the radio electrical connectors, or by disconnecting the battery, the radio is rendered inoperative . The radio is not permanently damaged, and proper operation can be restored by entering the radio anti-theft code .

RADIO AND SPEAKER SERVICE Radio, removing and installing CAUTION-

" Before beginning work on the radio or sound system, verify that the radio is an original equipment BMW radio and that the wiring harness has not been modified. " Servicing ofaftermarket sound equipment should be referred to an authorized agent of the equipment's manufacturer . " Do not remove radio or disconnect the battery without first obtaining the anti-theft code.

1 . Carefully pry open small square covers at left and right sides of radio.

Fig. 3. Ten speaker sound system .

RADIO AND SPEAKER SERVICE

RADIO 2. Using special hex key, turn radio mounting screws counterclockwise to loosen . See Fig . 4 .

650-3

Left footweil speaker, removing and installing

1 . Remove screw from center of hood latch release lever. Remove lever. See Fig. 6.

0011845

Fig. 4. Use special hex key or Torx driver to loosen/tighten radio mounting screws . 3. Pul¡ radio out of instrument panel opening. 4. Remove connector(s) from rear of radio. See Fig. 5.

Fig. 5. Radio connector being removed. 5. Installation is reverse of removal .

Fig. 6. Hood release lever retaining screw (arrow).

0012578

2 . Rotate plastic trim panel retainer 1/4 turn . Pul¡ off door sea¡ from edge of speaker cover and pull speaker trim panel back toward rear of car . See Fig. 7.

0011846 0012579

Fig. 7. Rotate plastic retainer (black arrow) and remove panel in direction shown (white arrows).

RADIO AND SPEAKER SERVICE

650- 4

RADIO

3. Remove speaker by removing mounting screws . See Fig . 8.

0012582

Fig. 10. Remove lower glove compartment trim panel retaining screw (black arrow) . Pull trim in direction shown (white arrows). Fig. 8. Speaker mounting screws (arrows) .

0012580

4. Disconnect harness connector(s) from speaker. See Fig. 9.

001,58

Fig. 9. Disconnect speaker electrical connector(s) in direction shown (arrows) . 5. Installation is reverse of removal.

Right footwell speaker, removing and installing 1 . Remove glove compartment lower trim . See Fig. 10 . 2. Rotate speaker cover plastic retainer 1/a turn . Remove door sea¡ at edge of speaker cover. See Fig. 11 . 3. Pul¡ speaker trim panel away from body and then pul¡ panel back toward rear of car.

RADIO AND SPEAKER SERVICE

0012583

Fig. 11 . Speaker cover retainer (black arrow) . Pull trim in direction shown (white arrow) . 4. Remove speaker by removing mounting screws . Disconnect harness connector(s) from speaker. 5. Installation is reverse of removal.

RAM Rear speaker, removing and installing NOTE -

Rear speakers in convertible models are installed under the rear side panels. For rear side panel removal procedure, see 411 Doors.

1 . Working at rear parcel shelf, pry speaker cover by inner edge and remove . See Fig . 12 .

650-5

Door panel speaker, removing and installing 1 . On cars with side-impact airbags, disconnect negative (-) cable from battery. CAUTION-

Prior to disconnecttog the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡.

2. Remove inner door panel . See 411 Doors. WARNING -

Some 1997 and all 1998 model year cars are equipped with front side-impact airbags in the front doors. When servicing the doors with front side-impact airbags, always disconnect the negative () battery terminal. See 721 Airbag System (SRS) for cautions and procedures relating to the airbag system .

3. On back of door panel, remove nut on top of speaker retaining bracket and remove bracket from behind speaker. See Fig. 14 . 0011632

Fig. 12 . Pry up inner edge of speaker cover off rear parcel shelf.

2. Remove mounting screws and depress speaker retaining clip . See Fig. 13 . Lower speaker into trunk.

Fig. 14. Speaker retaining nut (arrow). 4. Disconnect speaker connector from harness connector and remove loudspeaker forward through door panel . Fig. 13 . Remove screws (A) and depress clip (B).

0011633

3. Disconnect speaker connector and remove speaker from box.

5. Installation is reverse of removal. Install side-impact airbag using new screws . See 721 Airbag System (SRS).

4. Installation is reverse of removal .

RADIO AND SPEAKER SERVICE

650-6

RADIO

Radio Connector

Table a. Radio Connector Terminal Designation

Table a lists radio connector terminal designations . The pin numbers are identified in Fig . 15 .

Connector Terminal

Terminals 1-17

2010 30 40 50 60 907 0 80110 120 130 140 150 160 170

1 Speaker, left front +

1 Speaker, right front +

1 Speaker, left rear +

1 Telephone mute feature (where applicable)

1 Positive (terminal R)

1 Front speaker, left

1 I-bus connection (diagnostics)

C1) Connector

9 10

Fig . 15 . Radio connector. See Table a .

0011850

Signal

Speaker, left front 1 Constant positive, Terminal 30 Speedometer signal for speed-sensitive volume control (where applicable)

1 Speaker, right front

1 Speaker, left rear

1 Illumination (terminal 58G)

Speaker, right rear

1 Ground (terminal 31)

Automatic antenna or window antenna amplifier or premium sound system amplifier

Not assigned

!'~_T-

RADIO AND SPEAKER SERVICE

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

SEAT BELTS

720-1

720 Seat Belts GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720-1 FRONT SEAT BELT ASSEMBLY . . . . . . . . 720-2 Automatic Front Seat Belt Lock Tensioners . . 720-2 Mechanical spring tensioner, disarming . . . . . 720-2 Front seat belt reel, removing and installing . . 720-3

REAR SEAT BELT ASSEMBLY . . . . . . . . . . 720-4 Rear seat belt, removing and installing (fixed seat back models) . . . . . . . . . . . . . . . .720-4 Rear seat belt, removing and installing (fold-down seat back models) . . . . . . . . . . . . 720-5 Center rear lap-belt, removing and installing . .720-5

GENERAL All E36 models are equipped with 3-point shoulder belts at four seating positions. On 4-door models, there is an additional lap belt in the center of the rear seat . Automatic seat belt tensioners are integrated into the front seat belt locks. Through the 1996 model year cars, a mechan¡cal spring tensioner is used . See Fig. 1 . On 1997 and later cars, a pyrotechnic (explosive charge) tensioner is used . Automatic seat belt tensioners are designed to automatically re-

tract and tension the seat belt by 55 mm (approximately 2 inches) in the event of an accident . The seat belt reel should lock when driving quickly through curves, during severe braking or in case of a collision. The automatic reel does not require any servicing and should never be opened . Belts that do not retract and/or lock properly should be replaced promptly.

1 . Seat belt lock boft 2. Seat belt lock with mechanical spring tensioner 3. Seat belt anchor bar (two-door models) 4. Seat belt anchor bolt 5. Seat belt reel bolt 6. Seat belt reel 7. B-pillar guide nut 8. B-pillar sliding guide 9. Convertible seat belt reel 10 .Convertible B-pillar guide

Fig. 1. Front seat belt components .

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

720-2

SEAT BELTS

WARNING " For maximum protection from injury, seat belts should be replaced as a set (including all hardware), if they are subject to occupant loading in a collision. " Seat belts should not be modified or repaired. The seat belt anchorage points should not be changed or modified. " Do not bleach or dye seat belt webbing. Webbing that is severely faded or re-dyed will not meet the strength requirements of a collision and must be replaced. " Seat belts should be periodically inspected for webbing defects such as cuts or pulled threads.

FRONT SEAT BELT ASSEMBLY

0012737

Fig . 2 .

Electrically adjustable front seat . Turn screw (A) to disarm mechanical tensioner. Display B tucos from green to red .

F19 .3 .

Manuallyadjustablefrontseat .Turnandlifttab(arrow)todis-

Automatic Front Seat Belt Lock Tensioners The procedure for disabling the mechanical spring tensioner used on early cars is covered below . On cars with the pyrotechnic (explosive device) tensioners, the orange harness connector should be removed from the tensioner any time the seat is removed . WARNING Both the mechanical and the pyrotechnic tensioners are powerful devíces and should be handled with extreme care.

Mechanical spring tensioner, disarming 1 . Remove front seat . See 520 Seats . 2 . Disarm tensioner-electrically adjustable seats : " Working at side of seat, turn activating/deactivating screw clockwise until display changes from green to red . See Fig . 2 . " Before reinstalling seat, turn screw until display changes back to green . NOTEGreen is armed. Red is disarmed. 3 . Disarm tensioner-manually adjustable seats : " Cut wíre tie next to tab on bowden cable . See Fig . 3 . " Turn and lift tab to disengage cable housing from seat bracket . " Disconnect cable end from seat lever. " When reinstalling, correctly engage tab end of cable into seat bracket and fasten in position using new wíre tie .

FRONT SEAT BELT ASSEMBLY

SEAT BELTS

720-3

Front seat belt reel, removing and installing 1 . On 4-door models : Remove seat belt anchor bolt from front seat . Refer to Fig. 1 . 2. On 2-door models : Remove seat belt anchor bar from rear of door sill . See Fig. 4.

Fig. 5. B-pillar seat belt guide nut trim (arrow).

0012672

Fig. 4. Two-door seat belt anchor bar (arrow). 3. On 4-door and coupe models : Remove plastic trim cover from B-pillar (rear door jamb pillar) sliding seat belt guide. Remove nut and guide loop . See Fig . 5. 4. On 4-door models : Starting at upper corners, peel rubber door seals away from B-pillar trim . Remove trim from B-pillar. 5. On 2-door models : Remove reas side panel. See 411 Doors. 6. Remove two bolts holding cross bracket to B-pillar . See Fig. 6. 7. Remove seat belt reel mounting bolt at base of B-pillar.

ou12a74

Fig. 6. B-pillar trim removed to show seat belt cross-bracket bolts (arrows) . 8. Disconnect harness connector from reel assembly. Remove reel and seat belt . 9 . Installation is reverse of removal. Tightening Torque " Front seat belt to seat (use thread locking compound) . . . . . 47 Nm (35 ft-Ib) " Front seat belt guide loop to B-pillar sliding anchor . . . . . . . . . . 31 Nm (23 ft-Ib) " Front seat belt reel to B-pillar . . . . . . . 48 Nm (36 ft-Ib)

FRONT SEAT BELT ASSEMBLY

720-4

SEAT BELTS

REAR SEAT BELT ASSEMBLY On 4-door E36 models, there are two 3-point shoulder belts and a center lap belt in back . On 2-door models, there is no center rear lap-belt . In models with the stationary rear seat back, the shoulder belt reels are bolted to the middle of the parcel shelf. In modeis with fold-down rear seat back, the shoulder belt reels are attached to the folding seat back. The rear seat belt assemblies are shown in Fig. 7.

Fig. 8. Remove rear shoulder belt reel trim cover from rear window shelf. Unclip plastic, then slide off shoulder belts as shown by arrows .

Fig. 7. Detafs of rear seat belt assembly .

Rear seat belt, removing and installing (fixed seat back modeis) 1 . Remove rear seat cushion and backrest. See 520 Seats. 2. Remove plastic trim cover over shoulder belt reels from rear window shelf. See Fig. 8.

Fig. 9. Remove rear window shelf. Speaker grilles and third brake light socket will have to be removed . The front of the shelf lifts off its clips (black arrows) before the shelf slides forward. 6. On 4-door models : Unbolt shoulder belt lock bolt from body next to rear door frame.

3. Remove rear window shelf. See Fig. 9.

7. On 2-door models : Remove rear side panel as described in 411 Doors. Unbolt shoulder belt lock bolt from body next to quarter panel .

4. Unbolt and remove shoulder belt reels.

8. Installation is reverse of removal.

5. Remove shoulder belt anchor bolt from beneath rear seat . NOTEThe shoulder belt anchor belts also hold the center lapbelt in place (where applicable) . Be sure to note relative positions of metal belt-end anchors in order to reassemble correctly.

REAR SEATBELT ASSEMBLY

WARNING Alignment tabs on seat belt reels must be reinstalled in their original positions

Tightening Torques " Rear seat belt reel bolt, anchor bolt, or lock bolt to body . . . . . . . . . . . . . . . 48 Nm (36 ft-Ib)

SEAT BELTS Rear seat belt, removing and installing (foid-down seat back modeis) 1 . Remove rear seat cushion . See 520 Seats. 2. Remove shoulder belt anchor bolt from beneath rear seat .

720-5

7. Gently pry off plastic trim at top of backrest and pull out seat belt reel from seat . NOTE-

The seat belt reel is held snugly by the backrest cushion. Moderate force will be needed to pulí ít out.

8. Installation is reverse of removal.

NOTE -

The shoulder belt anchor bolts also hold the center lapbelt in place (where applicable) . Be sure to note relative positions of metal belt-end anchors in order to reassemble correctly.

3. On 4-door models: Unbolt shoulder belt lock bolt from body next to rear door frame. 4. On 2-door models : Remove rear side panel as described in 411 Doors. Unbolt shoulder belt lock bolt from body next to quarter panel . 5. Unlock and flip down folding rear seat backrest . Remove trim plug from back of cushion (luggage compartment side). 6. Remove seat belt reel bolt and washer. See Fig. 10 .

Tightening Torques " Rear seat belt reel bolt, anchor bolt, or lock bolt to body . . . . . . . . . . . . . . . 48 Nm (36 ft-Ib)

Center rear lap-belt, removing and installing 1 . Remove rear seat cushion. See 520 Seats. 2. Remove shoulder belt anchor bolts from beneath rear seat . NOTE-

The shoulderbeltanchorbolts also hold the centerlapbelt in place. Be sure to note relative positions of metal belt-end anchors in order to reassemble correctly.

3. Installation is reverse of removal. WARNING Alignment tabs on seat belt reels must be reinstalled in their original positions.

Tightening Torques " Lap-belt reel bolt or lock bolt to body . 48 Nm (36 ft-Ib)

Fig. 10. Rear seat belt reel bolt (arrow) .

0012676

REAR SEAT BELT ASSEMBLY

AIRBAG SYSTEM (SRS)

721-1

721 Airbag System (SRS) GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721-1 Airbag Systems . . . . . . . . . . . . . . . . . . . . . . . . 721-1

Front side-impact airbag crash sensor, removing and installing . . . . . . . . . . . . . . . . . 721-5

AIRBAG SENSORS AND ELECTRONICS 721-2

AIRBAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .721-5

SRS Warning Light and Fault Display . . . . . . . 721-2 Airbag contact ring, replacing . . . . . . . . . . . . . 721-3 Airbag crash sensor, replacing . . . . . . . . . . . . 721-4 ZAE control module, replacing . . . . . . . . . . . . 721-5

GENERAL

Driver side airbag, removing and installing . . .721-5 Passenger side airbag, removing and installing . . . . . . . . . . . . . . . . .721-6 Front side-impact airbag, removing and installing . . . . . . . . . . . . . . . . .721-7

WARNING -

This repair group covers only removal and installation of airbag components . Airbag system repair and fault diagnosis is not covered here . Diagnostics, component testing, and airbag system repair should be carried out by trained BMW service technicians.

" Airbag(s) are inflated by an explosive device. Handled improperly or without adequate safeguards, the System can be very dangerous. Special precautions must be observed prior to any work at or near the driverside airbag, the passenger side airbag (where applicable) or the side-impact airbags (where applicable).

NOTESpecial test equipment is required to retrieve SRS fault codes, diagnose system faults, and resetltum off the SRS indicator light. The SRS indicator light will remain on until any problem has been corrected and the fault memory has been cleared.

" The airbag is a vehicle safety system. Serious injury may result if System service is attempted by persons unfamiliar with the BMW SRS and its approved service procedures. BMW advises that all inspection and service be performed by an authorized BMW dealer.

When servicing cars equipped with SRS, the precautions on this page must be observed to prevent personal injury .

" Always disconnect the battery and cover the negative () battery terminal with an insulator before starting diagnostic, troubleshooting or service work not associated with SRS, and before doing any welding on the car.

Airbag Systems The airbag system installed on E36 cars through the 1993 model year consisted of a single airbag in the steering wheel. This system can be identified by the orange crash sensors located on the front wheel wells and the absence of a passenger side airbag . The ZAE airbag system, starting in model year 1994 (production date 9/93 and later), provides both a driver side and a passenger side airbag . On ZAE vehicles, the crash sensors are integrated into the airbag control module, located under the center of the rear seat. The ZAE control module triggers deployment of the airbags When it sensos the vehicle decelerating at a rate equivalent to a head-on collision of at least 13 mph (18 km/h). In some 1997 4-door models and all 1998 models, side-impact airbags were installed in the front doors. The airbag units are mounted behind the door trim panels . Caution must be used when working on vehicle systems in the proximity of air bags, such as the steering column, the dashboard, or the doors.

" If an airbag has been activated due to an accident, BMW specifies that SRS components be replaced. For more information on post-collision SRS service, see an authorized BMW dealer. " Do not allow the airbag unit to come in contact with cleaning solutions or grease. Never subject an airbag unit to temperatures aboye 212°F (100°C). When reconnecting the battery, no person should be inside the vehicle. " Always place an airbag unit that has been removed from its packaging with the padded side facing upward. Do not leave an airbag unlt unattended. " !f the airbag unit or airbag control module has been dropped from a height of !12 meter (1 Y2 ft.) or more, the airbag unit should not be installed.

Aírbag system components are shown in Fig. 1 .

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

721-2

AIRBAG SYSTEM (SRS)

1 . Crash sensors (through 1993)

2. SRS control module in front of glove compartment (through 1993) 3. Passenger side airbag unit in dashboard (ZAE system) 4. Driver side airbag unit in steering

wheel

5 . Side-impact airbags (1997/98)

6. ZAE control module under rear seat (from 1994) 7. Side-impact airbag crash sensors in door silis (1997/98) 8. Knee bolsters

Fig. 1 . Airbag system components .

AIRBAG SENSORS AND ELECTRONICS CA UTION" If an airbag is activated, the following components must be replaced: Airbag with contact ring; -Pyrotechnic seat belt tensioners (if fitted); -SRS Control module; -Impact sensors; All airbags which did not deploy. " Consult your BMW dealer for parts and service information .

The E36 airbag system consists of the following components: crash sensors (in early cars, through 1993), an electronic control/monitoring module (with integrated crash sensor in ZAE systems), an indicator light in the instrument panel, and inflatable airbags equipped with gas generators in the steering wheel and in the passenger side of the instrument panel (ZAE systems) .

In addition to the airbags, the vehicles are equipped wíth knee bolsters for extra protection .

SRS Warning Light and Fault Display The airbag system utilizes a self-diagnostic control module to detect and store system faults . If a fault is detected, the SRS indicator in the instrument cluster comes on and stays on . When the ignition key is tumed on, the indicator light will illuminate for approximately 4-6 seconds. The illuminated light indicates the self-test of the electronic control/monitoring module, the ignítors and crash-sensorcircuits, and the system wiring . The airbag system should be inspected by an authorized BMW dealer if the indicator light does not come on, if it does not go out in approximately 4-6 seconds after switching on the ignition, or if the light comes on during driving. If the system has detected a fault, the light will come on and stay on .

Some 1997 and al¡ 1998 cars also have side-impact airbags in the front doors.

AIRBAG SENSORS AND ELECTRONICS

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

AIRBAG SYSTEM (SRS) Airbag contact ring, replacing The airbag contact ring is mounted to the rear of the steering wheel and is made up of a wire ribbon that cofs and uncoils as the steering wheel is tumed. The contact ring assures continuous electrical contact to the driver side airbag unit .

721-3

7. Remove mounting nuts or screws from contact ring . See Fig. 3. Disconnect wire lead(s) and remove contact ring from rear of steering wheel.

1 . Disconnect negative (-) cable from battery and cover negative terminal with insulating material . CA UTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

2. Remove driver side airbag from steering wheel. See Driver side airbag, removing and installing in this repair group. 3. With wheels facing straight ahead and steering wheel centered, remove steering wheel . See 320 Steering and Wheel Alignment. 4. Remove contact ring cover (flat plastic ring containing warning text) from steering wheel, íf applicable . 5. Disconnect ground wire, if applicable 6. Lift out plastic lock from steering wheel, if applicable . See Fig . 2.

Fig. 3. Airbag contact ring mounting fasteners (arrows) .

0011904

8. Installation is reverse of removal, noting the following:

" Coat horn slip ring (electrical contact ring) with CRC® copper paste before installing steering wheel. " Press on lower lock until it ís fully engaged. " When installing contact ring lock, make sure lock spring engages pins on lock and lock cover. " Special instructions apply when installing airbag equipped steering wheel . See 320 Steering and Wheel Alignment.

Early cars (through 1993): " Route wiring lead for horn through square opening in steering wheel. " When installing a new contact ring from BMW, remove locking screw after installing the contact ring to steering wheel. See Fig. 4. " Lock contact ring mounting fasteners in place using lacquer paint or varnish .

0011903

Fig. 2. Airbag contact ring lock (arrow). Pry out lock and remove spríng from behind lock . Some airbag steering wheels are not equipped with contact ring lock . WARNING " The contact ring lock holds the contact ring in the centered position . Once the lock is removed, the contact ring is free to rotate. Do not allow the contact ring to rotate once the lock is removed. " If the contact ring is accidentally rotated out of center, turn the ring either fully clockwise or counterclockwise, then turn in the opposite direction 3 complete revolutions until the alignment arrow can be seen through the lock opening.

Fig. 4. Airbag contact ring locking screw (arrow), as installed on new replacement part from BMW (early production cars).

AIRBAG SENSORS AND ELECTRONICS

721-4

AIRBAG SYSTEM (SRS)

CAUTION-

A new contact ring is held in center position with a screw. This locking device must be removed after contact ring is installed on steering wheel. See Fig . 4.

2. Remove lower steering column trim mounting screw and remove lower trim . See Fig . 6 .

Later cars (1994 on): " Connect ground lead at contact ring . " When installing a new contact ring from BMW, remove locking pin after installing contact ring to steering wheel . See Fig . 5 .

0012543

Fig . 6 .

Lower steering column retaining screw (arrow) .

3 . Remove orange SRS connector from its holder and carefully separate connector. See Fig . 7 .

Fig . 5 . Airbag contact ring locking pin (arrows), as installed on new replacement part from BMW (later production cars) . Contact ring mountíng screws shown at A .

CAUTION-

A new contact ring is held in center position with a screw or pin. This locking device must be removed after contact ring is installed on steering wheel. See Fig. 5. 0011891

Airbag crash sensor, replacing The airbag system in cars produced through 1993 uses two crash sensors mounted in the engine compartment on the left and right wheel arches . The sensors are identified by their orange color . WARNING If en airbag is deployed, both sensors must be replaced. 1 . Disconnect negative (-) cable from battery and cover negative terminal with insulating material .

CAUTION-

Prior to disconnectiog the battery, read the battery disconnection cautíons given at the front of thls manual on page viii.

AIRBAG SENSORS AND ELECTRONICS

Fig . 7 . Orange SRS connector below steering column (arrow) .

4. Working in engine compartment, remove anti-tamper Torx screws from crash sensor. Remove sensor and disconnect harness connector . See Fig . 8 . 5. Installation is reverse of removal . Make sure arrow on sensor faces forward when installing sensor. WARNING Once the airbag unit is installed and all other service procedures have been completed, start the engine and check that the SRS warning light goes out. If the warning light stays on, the SRS system will not function as designed. Have the system diagnosed and repaired by en authorized BMW dealer.

AIRBAG SYSTEM (SRS)

721- 5

AIRBAGS Driver side airbag, removing and installing 1 . Disconnect negative (-) cable from battery and cover negative terminal with insulating material . WARNING On cars with ZAE system: If the airbag system has detected a fault (SRS indicator illuminated), a waiting period of at least ten minutes must be observed before removing the airbag from the steering wheel. This will allow the system capacitor to discharge, reducing the possibility of a trigger pulse being generated to the airbag.

Fig . 8 . Airbag crash sensor mounting screws (arrows) on early cars . Note Torx screws with anti-tamper pin in screw-head .

CAUTION-

ZAE control module, replacing

Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page vi¡¡.

NOTE-

Some versions of early ZAE control modules are no longer available from BMW. When replacing control modules on cars built between September 1993 and June 1994, consulta BMW parts department for the latest information on retrofitting the later module. 1 . Disconnect negative (-) cable from battery and cover negative terminal with insulating material . 2 . Lift rear seat cushion . Unplug harness connectors and remove ZAE airbag control module, which is bolted to top of driveshaft tunnel .

2 . Remove lower steering column trim mounting screw and remove lower trim . Refer to Fig . 6 . 3 . Remove orange SRS connector from its holder and carefully separate connector. Refer to Fig . 7 . 4. Working behind steering wheel, completely loosen Torx screws (T30) while holding airbag in place. See Fig . 9 . Support airbag unit to prevent it from falling out .

3 . Installation is reverse of removal .

Front side-impact airbag crash sensor, removing and installing 1 . Disconnect negative (-) cable from battery and cover negative terminal with insulating material . 2 . Remove front seat . See 520 Seats . 3 . Convertible : remove rear seat 4. Remove plastic door sill trim . 5. Fold up carpet in back of front seat .

Fig . 9.

Driver side airbag unit mounting screws (arrows) .

0011893

6 . Pull off connector from crash sensor, which is located under rug next to door si¡¡ . 7 . Remove sensor by removing screws . Note direction arrow before removing sensor. 8 . Installation is reverse of removal, noting direction arrow on sensor.

AIRBAGS

721-6

AIRBAG SYSTEM (SRS)

5 . Carefully lift airbag unit off steering wheel and disconnect orange harness connector from rear of airbag unit . See Fig . 10 . NOTEIn some models, the airbag electrical connection to the steering wheel is via a plug in back of the airbag unit. There is no wire harness to disconnect.

6 . Installation is reverse of removal . Tighten right side screw on airbag first (as viewed from driver's seat), then left side screw. NOTEIf there is no electrical harness connector between the airbag and the steering wheel, be sure to fit the push in electrical plug in back of the airbag finto the proper receptacle in the steering wheel.

Tightening Torque " Airbag unit to steering wheel . . . . . . . . 8 Nm (71 in-lb)

Passenger side airbag, removing and installing 1 . Disconnect negative (-) cable from battery and cover negative terminal with insulating material . 2 . Remove glove compartment . See 513 Interior Trim . 3 . Lift cover from top of passenger side airbag on dashboard . See Fig. 11 .

Fig . 10. Driver side airbag unit harness connector (arrow) .

0013184

WARNING " Store the removed airbag unit with the horn pad facing up. If stored facing down, accidental deployment could propel it violently into the air, causing injury. " Once an airbag is removed, the car must not be driven . " Do not connect the battery with the airbag disconnected . A fault code will be stored, setting off the SRS warning light. Special tools are needed to reset the fault memory. " Special instructions apply when installing an airbag equipped steering wheel. See 320 Steering and Wheel Alignment . " Once the airbag unit is installnd and all other service procedures have been completed, start the engíne and check that the SRS warning light goes out. If the warning light stays on, the SRS system will not function as designed. Have the system diagnosed and repaired by an authorized BMW dealer.

AIRBAGS

0013108

Fig . 11 . After removing glove compartment, lift out passenger side airbag cover. Note airbag mounting bolts (A) and airbag electrical connector (B) . 4. Remove passenger side airbag mounting bolts . Disconnect electrical harness connector from rear of airbag unit and remove airbag . 5 . Installation is reverse of removal . Make sure wiring harness is not pínched when installing airbag unit in dashboard .

AIRBAG SYSTEM (SRS) Front side-impact airbag, removing and installing 1 . Disconnect negative (-) cable from battery and cover negative terminal with insulating material . CA UTION-

Prior to disconnectiog the battery, read the battery disconnection cautions given at the front of this manual on page viii.

721-7

CAUTION-

" The electrical harness connector of the side-impact airbag unit may be either on the side of the unít or in the back When removing and installing the unit, pay attention to the routing of the harness to avoid kinks orbreaks in the wire . " Store the removed airbag unit with the soft pad facing up. ff stored facíng down, accidental deployment could propel it violently into the air, causing injury.

2. Remove inside door panel as described in 411 Doors. Remove vapor shield .

4. Remove mounting screws and remove airbag from door.

3. Disconnect electrical harness connector from doormounted airbag unit . See Fig. 12 .

5. Installation is reverse of removal. WARNING -

The side-impact airbag mounting screws must always be replaced any time they are removed. Use new screws with factory-applied locking sealer.

Tightening Torque " Side-impact airbag to door . . . . . . . 8.5 Nm (75 in-lb)

Fig. 12. Front side-impact airbag (inner door panel removed) . A is electrical harness connector. WARNING -

The plug connector inside the door is not marked in orange, unlike other SRS connectors in the car.

AIRBAGS

ELECTRICAL WIRING DIAGRAMS

ELE-1

Electrical Wiring Diagrams GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELE-1 ELECTRICAL WIRING DIAGRAMS . . . . . . ELE-2 ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELE-117 ABS/AST . . . . . . . . . . . . . . . . . . . . . . . . . . . ELE-120 Airbag (Supplemental Restraint System) . . ELE-140 Air Conditioning and Heating . . . . . . . . . . . ELE-129 Anti-Theft (Alpine) . . . . . . . . . . . . . . . . . . . . ELE-144 Anti-Theft (EWS II) . . . . . . . . . . . . . . . . . . . ELE-150 Body Computer Module . . . . . . . . . . . . . . . ELE-176 Charging System . . . . . . . . . . . . . . . . . . . . . ELE-67 Convertible Top . . . . . . . . . . . . . . . . . . . . . . ELE-253 Cruise Control . . . . . . . . . . . . . . . . . . . . . . . ELE-112 Data Link Connector . . . . . . . . . . . . . . . . . . . ELE-86 Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . ELE-94 Engine Management . . . . . . . . . . . . . . . . . . . ELE-70 Exterior Lights . . . . . . . . . . . . . . . . . . . . . . . ELE-194 Ground Distribution . . . . . . . . . . . . . . . . . . . . ELE-35 Headlights/Foglights . . . . . . . . . . . . . . . . . . ELE-180 Heated Seats . . . . . . . . . . . . . . . . . . . . . . . ELE-245

Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELE-153 Instrument Panel . . . . . . . . . . . . . . . . . . . . ELE-165 Interior Lights/Illumination . . . . . . . . . . . . . ELE-211 Lumbar Control . . . . . . . . . . . . . . . . . . . . . ELE-247 On-Board Computer . . . . . . . . . . . . . . . . . . ELE-173 Park Ventilation . . . . . . . . . . . . . . . . . . . . . ELE-139 Power Distribution . . . . . . . . . . . . . . . . . . . . . ELE-2 Power Door Locks . . . . . . . . . . . . . . . . . . . ELE-226 Power Mirrors . . . . . . . . . . . . . . . . . . . . . . . ELE-241 Power Seats . . . . . . . . . . . . . . . . . . . . . . . . ELE-243 Power Sunroof . . . . . . . . . . . . . . . . . . . . . . ELE-248 Power Windows . . . . . . . . . . . . . . . . . . . . . ELE-231 Radio/Cassette/CD/Speakers . . . . . . . . . . ELE-255 Rear Window Defogger . . . . . . . . . . . . . . . ELE-160 Shift Interlock . . . . . . . . . . . . . . . . . . . . . . . ELE-110 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELE-63 Transmission Electronics . . . . . . . . . . . . . . . ELE-96 Warning System : Chimes . . . . . . . . . . . . . ELE-178 Wiper/Washer . . . . . . . . . . . . . . . . . . . . . . ELE-155

ELECTRICAL COMPONENT LOCATIONS Relay and fuse positions, ground locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Repair Group 610

GENERAL This section contains wiring diagrams for 1992 through 1998 BMW 3 Series models . WARNING On cars equipped with airbags, special precautions apply to any electrical testing or repair. The airbag unit is an explosive device and must be handled with exterme care. Before starting any work on an airbag equipped car, refer to the warnings and cautions in 720 Seatbelts and 721 Airbag Systems (SRS). NOTE" The gear position/neutral safety switch is also sometimes referred to as the automatic transmission range switch . " The EWS 11 system is also sometimes referred to as the Driveaway Protection System or the electronic immobilization system .

CAUTIONAlways switch the ignition off and disconnect the negative (-) battery cable before removing any electrical components. " Prior to disconnecting the battery, read the battery disconnection cautions given at the front of this manual on page viii. " Connect and disconnect ignition system wires, multiple connectors and ignition test equipment leads only while ignition is switched off. -Always switch a test meter to the appropiate function and range before making test connections. " All-Season Traction (AST) is also referred to as ASC or ASC+T.

GENERAL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE--2

ELECTRICAL WIRING DIAGRAMS Power Distribution

1992-93 318i Only (1 of 7) BNUMPSTART JUNCTION POINT

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RIGHTPOWER WINDOW MODULE

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Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

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LIGHT SWITCH

-I

LOWBEAM LIGHTRELAY

AUTOMATIC TRANSMISSION RANGESWITCH

FUSEF24 (DIAGRAM30F7)

PROGRAM SWITCH

INSTRUMENT CLUSTER

___________-----1FRONTPOWER CI

DISTRIBUTION BC FUSE F23 SA

FUSE F22 SA

DATA LINK CONNECTOR

1 AUXILIARY CONNECTOR

FROM

FUSE F21 5A 2

REVERSING LIGHTSWITCH

CANADA

"-1993 ONLY

I v

vv _I

INTEGRATED CLIMATE REGULATION CONTROL MODULE 64776

I~ v

i v

COMBINATION SWITCH

I i ~ v INSTRUMENT CLUSTER

I v

REAR DEFOGGER RELAY

I i ~ v JETHEATER THERMOSWITCH

I v

MULTIFUNCTION CLOCK

I iv v UNLOADER RELAY

DAYTIMERUNNING LIGHTSCODING DIODE

I i v v

LIGHT SWITCH

ASSSLIP CONTROL MODULE

ABSRELAY

CAL WIRING DIAGF

Power Di : 1992-93

FROMFRONTPOWER DISTRIBUTION BOX (DIAGRAM 1 620F7)

RED 1

FRONTPOWER DISTRIBUTION BOX

i 1592 ONLY ONLY

I I

ASSRELAY

3 3

ANTI-THEFT CENT I REAR I I LEFT I I RIGHT I I LEFT I I RIGHT I ITRUNKI RAIL ANTI-THEFT I HORN I DEFOGGER DOOR DOOR DOOR DOOR LOCK LOCKING CONTROL RELAY CONTROL RELAY LOCK LOCK LOCK LOCK MOTOR MODULE MODULE MODULE SWITCH SWITCH MOTOR MOTOR

RED/WHT

3 O

WI STEREO 6- SPEAKER W/HIFI,TEN SVSTE~~PEAKERSYSTEM

I I

_I UNLOADER RELAY

I -I

I I

RADIO

I _I RADIO

I - I

I I

o z

I I

_I HIF' AMPLIFIER

CD CHANGER

r________________________________________________-FRONT I I I

FUSE F31 5A

. FUSE .. .. .. . . . . . . . . . .. F32 30A

----- ______ z

FUSE F33 I,0 OA

3 a

FRONT CIGAR LIGHTED

Y I

I I

_I KIM

3 I I

I I

18 -

i I

! ___I INTEGRATED CLIMATE RECIRCULATION CONTROLMODULE

CONTROL I" PANEL

( I

! _I CHIME MODULE

TFUSEF33 ODAORAM SOFT)

! _I MULTIFUNCTION CLOCK

I I

i -I_ INSTRUMENT CLUSTER

FUSE F34

FUSE z'235

FUSE 136

FUSE F37 t0A -

64784

I I

- I

I I

II I

CHARGING SOCKET

_I I I

I I

1 I I

I -I FRONT DOME/ MAP LIGHT ASSEMBLY

LEFTPAPK LIGHTRELAV

i I

I _I LEFT POW WINDON MODULE

FUSE FUSE F38 30=~

CENTRAL LOCKING MODULE

I I WIPER RELAY

I I

FRONT I POWER (DISTRIBUTION BOX

1 I

WIPER/ WASHER MODULE

I I LIGHT SWITCH (USA)

8 I I

2 I I

TRUNK COMPARTMENT LIGHT

11 I I

RED/WIT

USA

HAZARD FLASHER RELAY

14Es

CANADA

CRASH CONTROL MODULE

W1 RASH CONTROL C MODULE

I I

1 _

LIGHT SWITCH

__________________-

RED/WHT

A-____

RED

______ R

22 -

G203 FROMFRONTPOWER DISTRIBUTION BOX (DIAGRAM 1 82OF7)

RED/WHT

I I

________J

REDIYEL

1 -

POWER I DISTRIBUTION BOX

FROM R FUSE (DIAGRAMSOF7)

I I

0 I I

RIGHTPARK/ LICENSEPLATE LIGHTRELAV (CANADA)

I I

ABSPUMP MOTORRELAV

I I

¢4

2 I I

RIGHTREAR INTERIOR LIGHT

I I

I 1

LEFTREAR INTERIOR LIGHT

I 1

16 I I

TELEPHONE TRANSCEIVER

ELE rower 1992-

F=eNT^nOW~^R~ u

RED

FROM FRONT POWER DISTRIBUTION BOX (DIAGRAM1&20F7)

RED

REO

18I

PED

1993

FROM FRONT ~ nm~n

RED

10 FROM FRONT POWER DISTRIBUTION BOX (DIAGRAM/ &20F7)

FROMFRONTPOWEn DISTRIBUTION BOX (DIAGRAM 1 &20F7)

1992

18 92

BLOWER RELAY

-I

I I

RIGHTSEAT CoNTROLSWITCH

I I

-- -

g ~ -

-___________________

4 -7 .5_______ _

I I

PARK HEATING VENTILATION RELAY BOX -- I FRONTPOWER I DISTRIBUTION BOX FUSE I F11 7 .5=~ _

FUSE F12

16A---__---

I I

NOTUSED

FROMLOWBEAM YEL LIGHTRELAY M (DIAGRAM/&20F7) ~ 1

FUSE F16

HEADLIGHT/ FOOLIGHT CLEANING No DULE(SPA) (CANADA)

RED/YEL

FUSE F20 30A

I I

LEFTSEAT CONTROLSWITCH

FROMFRONTFOG LIGHTRELAY - - (DIAGRAM/&20F7)

I I

1992 OR 1993W/O PARK VENTILATION

1993W/PARK VENTILATION

GRNIBRN WIOCCM

. 1

FROMFRONTPOWER DISTRIBUTION BOX (DIAGflAMi&20F7)

BLOWER RELAY

FROMFRONTP0 ER DISTRIBUTIONBOX (DIAGRAM 1 & 2 OF 7)

RED 21

I I I

64849

------

FUSE F41 -----------2z

HIGHSPEED RELAY

FOG LIGHT

FROMFRONTFOG LIGHTRELAV V (DIAGRAM l & 2 OF 7)

RED

---------

I I

INSTRUMENT CLUSTER

W/OCCM

r-___-

!____

LEFT LOW BEAM HEADLIGHT

I I ! _I

CHECKCONTROL MODULE

RIGHTLOW BEAM HEADLIGHT

CANADA

e I I

(_)

FOGLIGHT

PARK HEATING VENTILATION RELAY BOX

W/CCM

I(-) I I I I BLOWER RELAY

6 e z a I-

W/C CM

I I

YELIBLK

-_---

_ FUSE F39 7 .BA -_--

FUSE F17 10A -_____

_- _____ 1a

t¢7

COMPRESSOR CONTROL RELAY

FRONT POWER

2z >

FROMHIGHBEAM REDIWHT LIGHTRELAY K (DIAGR=M1&20)=7)~ 1

I I

I DISTRIBUTIONBOX I

FUSE F30 7 .BA-____

CANADA

FUSE F28 7 .0= -~

;

I I

REARFOG LIGHTSWITCH

I I

RIG THIGH BEAM LIGHT

I I

LEFTHIGH BEAM LIGHT

CAL WIRING DIAGR

Power uis 1992-93

FROMFRONTPOWER DISTRIBUTION BOX (DIAGRAM 1 &20F7)

1 3202 O

1 FRONTPOWER I DISTRIBUTIONBOX

FUSE F1 30

I I

-J

2 O

AUTOMATIC CUT-OUT

9 I

CENTRAL LOCKING MODULE

I I

SUNROOF CONTROL ASSEMBLY

I I

5 I I

LEFT REAR 000RPOWER WINDOWSWITCH (CONSOLE) 64850

I I

5 I I

RIGHT EAR DOORPOWER WINDOWS WITCH (CONSOLE)

I I

3 I I

CHILD PROTECTION CONTROL (CONSOLE)

~ I

I I

LEFT POWER WINDOW MODULE

I I

3 I I

LEFT POWER WINDOW SWITCH

I I

3 I I .

RIGHTPOWER WINDOW SWITCH

ELE

Power E

1994-95 Exc JMPSTART C710NPOINT

., . ..

---

RED

REO

FUSIBLE LINK

W/TRUNK MOUNTED BATTERY

W/ENGINE MOUNTED BATTERY

_ _ BATTERY

0 GENSTARTER ¢ JUNCTION POINT ERATOR

1994

o w

_--I

ENGINE CONTROL MODULE RELAY 28

w 14

-_- I

I__I TRANSMISSION CONTROL MODULE (EGB)

! _I OXYGEN SENSOR RELAY (4CYL)

! _I ENGINE CONTROL MODULE

w 7

FUEL PUMP RELAY

r 1

I~ I

-_I

( P U M P/ S T ART IJRELAY

! _I TRANSMISSION CONTROL MODULE(EGS)

! ___I ENGINECONTROL MODULERELAY

I I

! ___I ENGINECONTROL MODULE BELAY

I I

! _I DOUBLE RELAY

DATA LI NK C. NN

STARTER

I ¢

GENERAT

RED

-1

USE

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ----RED RED C TO FUSE 15 . 2 1 0 X TO FUSEF47 (DIAGRAM50F5) (DIAGRAMSOF5) --RED RED 0 TO FUSEF40 TO TUBEF20 B (D(AGRAM 5 0F 5) (DIAGRAM 5 0F 5) 1994 RED R" RED E TO ID IGNITION SWITCH 70 FUSE F3 A IAGRAM2OF5) (DIAGRAM5OF5)

2 I

I I

I -I

TO FUSE(DIAGRAMSORS)

RED

TOFUSEF39 (DIAGRAMSOFS)

RED

FUEL PUMP fi

6 O BEAM LIGHT RELAY

(

5 NOTUSED

TOFUSE '48 (DIAGRAMSOFS I (1 9 9 5)

g I FRONT FOG ( LIGHT j~( RELAY

I I 5

2 _

HIGH I BEAM ( LIGHT I ~j RELAY I~

TOFUSEFIS (DIAGRAM 5DF5/

TOFUSEF29 (DIAGRAM SOBS)

TOFUSEFI7 IDIAGRAM50F5(

18 I I

RED

¢ 7

FUBE F4 5

I _I BODY ELECTRONICS CONTROL MODUL.(ZKEIV)

I I

v B

I I

FUSE 2F2

I_ I UNLO ADERRELAY TERMINAL15

TOCOMFORTR (DIAGRAMSOF

TO ' .BE P.1 (DIAGSAM4OF

70 FUSE FB (DIAG RAM 4 OF

3 FUSE 14 S

8 I I

RED

TOFUSEF11 (OIAGRAMSOFS)

2 CANADA

FRONT POWER I DISTRIBUTION BOX

RED

TO FUSEFI9 (DIAGRAMSOF5)

83172

P1B

3251,3251 ., 3251 CONVERTIBLE

GRN/VIO

_--

ENGINE CONTROL MODULE

3181,37815, 3181 CONVERTIBLE

w 2fi

FUEL' PUMP/ START RELAY Lz

I2 I

I B

REO

BATTERY

14 DATA LINK CONNECTOR

B+ JUNCTION POINT

~~ Y 1994 1995

D RED

81 JS

DATA LINK CONNECTOR

I__I ENGINE CONTROL MODULE

61 .'S._¢

PUMP

I R ELAY

' - yJ

DATALINK CONNECTOR

(

II I

III

LINK

ENGINECON7ROL MODULERELAY x1995 + "

BATTERY

CONNECTOR

-I STARTER

x1994 + .

RED

TION I JUONCINT P

- I

GENERATOR

o B+

I I I

I I

m ¢

Iffm

W/TRUNK MOUNTED BATTERY

RED

Fil

B+JUMP START JUNC710NPOIN7

RED

-I BODY EI LCTRDNCS CONTROL MODULE(ZKEIV)

AUXILIARY CONNECTOR (19)

I FRONTPOWER OISTRIBUTIONBCX

lICAL WIRING DIAG

Power Di:

1994-95 Excep FROMFRONTPOWER ~A I ~+ DISTRIBUTION BOX (DIAGRAM 10F5) I ~~ 5

-----_

BLKIVEL (OR GFN/BLK)

O TO FUSE F16 (DIAGRAM 3 OF 5)

(7 5 _ _

ORN

FUSE USE F24 F2 (DIAGRAM30F5)

GRN

O B

I I

P V

NOT USED

I I

STARTER IMMOBILIZATION RELAY (1994) ELECTRONIC IM MOB LIZ PCONTROL NoDULE(WS1)_ (1995)

BLOWER RELAY

INSTRUMENT CLUSTER

TO FUSE F28 TO USE F

(DI

IGNITION

I I

IGNITION coll .,

ENGINECONTROL MODULE(DME)

IGNITION CO L12

I I

IGNITION CO L13

I I

IGNITION CO ILN4

IGNITION ILk5 (IFEOUIPPED) Co

TOFUSEF45 (DIAGRAM 3015)

TOFUSEF46 (DIAGRAM 3 OF 5)

122>7t

..111I~~~ FRONT POWER I DISTRIBUTION BOX FUSE 11 FUSE / ------------------15A

FUSE . . . .. .. . . . .. . . . . . . . . . . . . . .. . . ..

3 o

24 24

¢o

z ~

I _I SP SCONTROL MODULE (LATE PRODUCTION)

IGNITION CO L#6 (IF EQUIPPED)

HORN RELAY

VIO

I I

VIO

I I

BODVELECTRONICS CONTROLMODULE (ZKE11) (1894)

> S

INSTRUMENT CLUSTER

> 15

VIO/l WHT VIOIWHT t I

VIOIWHT T 3

1 I

I I

_I ROLLOVER SENSOR

H 3

_I FRONTDOME/ MAP LIGHT ASSEMBLY

I I

(

I I

- I

-I

CO ANTI THEFT NTROLMODULE

I I

GLOVEBOX LIGHT

_ I BODVELECTRONICS CONTROLMODULE (ZKEIV)

RIGHTMAKEUP MIRRORLIGHT

> 5

23 I I I

I I -I

> 4 I I

I I

_ I RADIO

WIPER/WASHER MODULE (CANADA)

I I

I _I TWINRELA' MODULE (CANADA)

VIO/WHT

> 3 I I

> 8 I I

LEFTMAXEUP MIRROR LIGHT 8317 3

I I

> 1

>~ 5 I I

CONVERTIBLE TOP CONTROL MODULE

I I

TELEPHONE TRANSCEIVER

I I

SEAT OCCUPANCY DETECTOR

I I

m O >

> 3

8 I

SWITCH SPATIAL SOUND (1995)

WIPER/WASHER MODULE (USA)

I I

WASHERPUMP (USA)

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-11

Power Distribution

1994-95 Except 318ti (3 of 5) FROMIGNITION SWITCH (DIAGRAM2OF5)

VIO T

FROM IGNITION SWITCH U (DIAGRAM20F5)

VIO

"I" IGNITION SWITCH (DIAGRAM20F5)

_________________________ _____________________ -_-

FUSE F46

141

I I

ON-BOARD COMPUTER

I I

CHECKCONTROL MODULE

FROMIGNITION SWITCH (DIAGRAM20F5)

I i

WIPERMOTOR RELAY

INSTRUMENT CLUSTER

WIPER RELAY

It 11

16/ Jll~~~

I i

I I

I i

> 261 JJJ..

BRAKELIGHT SWITCH

FRONTPOWER I DISTRIBUTION BOX I

FUSE F18

CRUISE CONTROL MODULE

j L - i

CRUISECONTROL SWITCH

- i

TRANSMITTER MODULE (EWSIN (1995)

- i

COMPRESSOR CONTROL RELAY

t - i

NORMAL SPEED RELAY

I I

HIGH SPEED RELAY

GRIN PROMIGNITION SWITCH ~(DIAGRAM20F5)

FUSE F24 10A

-FUSE F26 10A -------

FUSE F25 5A

------------------

FUSE F27 5q

,FRONT (POWER DISTRIBUTION (BOX

I I

23 INSTRUMENT CLUSTER

I I I I -I I

AUTOMATIC TRANSMISSION RANGESWITCH

JET HEATER (

MIRROR CONTROL SWITCH

994)

WIOEGSONLV -- I

L LEFT PARK LIGHT RELAY (CANADA) (1894)

_I-

I _I INTEGRATED CLIMATE REGULATION CONTROL MODULE 8317 4

I I

LIGHT SWITCH

I I

I I I_ -)

I I

RIG H7 PARK LIGHT/LICENSE PLATE LIGHT RELAY (CANAD A) (1 994 )

LOWBEAM LIGHT RELAY (CANADA) (1994)

I _I

"1" AUXILIARY CONNECTOR

HIGH BEAM LIGHT RELAY (1995)

AUTOMAT IC TRANSMISSION RANGESWITCH

PROGRAM SWITCH

HROTTLE THROTTLE FLAP HEATER

STARTER IMMOBILIZATION RELAY (1994 LATE PRODUCTION) SERVOTRONIC CONTROLMODULE (1995) FRONTPOWER I DISTRIBUTIONBOX

FUSE F23 5A

FUSE F22 5A

FUSE F21 5A

I I

DATA LINK CONNECTOR

REVERSING LIGHT SW TO

I I

FROM FU SEF24 (DIAGRAM 30F5)

I I I

I I

L I I

! --- I COMBINATION SWITCH

41 I I

4, 1 I I

! _I INSTRUMENT CLUSTER

I I

91 I I

! _I PEAR DEFOGGER RELAY

I I

8t I I

MULTIFUNCTION CLOCK

I I

el I I

UNLOADER RELAY

I I

8), I I

SLIP CONTROL MODULE (AB S) (1995)

I I

LIGHT SWITCH

I I

531 I

ASC SWITCH

ABSSLIP CONTROL MODULE

I I

i I

ASS RELAY

ELECTRICAL WIRING DIAGRAMS

ELE-12

Power Distribution

1994-95 Except 318ti (4 of 5) RED

"~ FROM ~IFRONTPOWER DISTRIBUTION BOX (DIAGRAM 1 OF 5)

-----------------------------------------------FUSE F6 20A

FRONT POWER

I DISTRIBUTIONBOX

FUSE FB 15A __-_____

FUSE F7 SA

REAR DEFOGGER RELAY

_ °l

LEFT DOOR LOCK SWITCH

RIGHT DOOR LOOK SWITCH

_ 8

28,

_1)

I I i I I I I ! _I L _I

I I I I I I I I I I I L _I ! _I ! _I I

LEFT DOOR LOCK MOTOR

18r

FUSE F9 20A W_ --

RIGHT DOOR LOCK MOTOR

TRUNK LID MACROSWITCH

TRUNK LID RELAY

--I

F I -I

L-1

CONVERTIBLE TOPSTORAGE LIDLOCK MOTOR

REDISLU

'.I.

181

3 h

I- i

I I I I L -I L -I

CONVERTIBLE TOPCONTROL MODULE

TRUNK LOCK MOTOR

_1~

FUSE 310 30A

I I ! _I

BODY ELECTRONICS CONTROLMODULE (ZKFIV)

I I L-1

sI I

HORN RELAY

z I I - I

I I

_ I HIFI AMPLIFIER

RADIO

_____-__________________-____________-__~FSONTPOWER I I I I

FUSE F31 SA

FROM I DISTRIBUTION BOX FUSE F34 (DIAGRAM 4OF5) I

FUSE F33 I OA

FUSE F32 30A

L"____________________________"_______J

RED/WH

11 I I

151 i I

31 I I

I I

INTEGRATED CLIMATE RECIRCULATION CONTROLMODULE

IHKR CONTROL PANEL

_ I I

CHIME MODULE

I I

_1 I I

MULTIFUNCTION CLOCK

I I

I --, I I

INSTRUMENT CLUSTER

L _I LIGHT SWITCH G203

FROM RED FRONTPOWER DISTRIBUTION BOX (DIAGRAM10F5) r _ _ R _____ 70 _F U_S E I. FUSE F33 F34 I (DIAGRAM

FUSE F35

25_____________

__G _5)__

_5___

I I

L _I CHARGING SOCKET

FUSE F36

JFUSE . . . . F37 1 .0A

FUSE F35

83175

HAZARD FLASHER RELAY

CENTRAL LOCKING MODULE

BODY ELECTRONICS CONTROLMODULE (ZKE IV)

WIPER RELAY

WIPER/ WASHER MODULE

LIGHT SWITCH (USA)

FONT I PD`N (DISTRIBUTION ( BOX

ABSPUMP MOTORRELAY

I I

L _I LEFT POWER WINDOW MODULE

RED/WIT RED/WHT

3D _J

RIGHTPARK/ LICENSEPLATE LIGHTRELAY (CANADA) (1994)

III

L _) FRONTDOME/ MAP LIGHT ASSEMBLY

F _______________________-__-

I I

L _I LEFTPARK LIGHTRFLAY (CANADA) (1994)

L _I TRUNK COMPARTMENT LIGHT

CRASH CONTROL MODULE

I --, I I

CONVERTIBLE TOPCONTROL MODULE (1995)

12 I I

L _I CD CHANGER

I I

4 I I

L _I BODY ELECTRONICS CONTROL MODULE (ZKE IV)

I I

16 I 1

! ___I TELEPHONE TRANSCEIVER

ELECTRICAL WIRING DIAGRAMS

ELE-13

Power Distribution

1994-95 Except 318ti (5 of 5) FROM FRONT POWER DISTRIBUTION BOX (DIAGRAM IOF5) 9

FROM RED O'S FRONTPOWER C TRIBUTIONBOX ~ - (DIAGRAM IOF5) 91

RED

FUSE F20 30A

FROM FRONT POWER D DISTRIBUTION BOX - (DIAGRAM IOF5)) ---

RED '

FUSE FS 30A

---------------

------------

FROM FRONT POW ER E DISTRIBUTION BOX - (DIAGRAM 101S)

RED

iFUSE F40 SPA ___-_________

FUSE F3 30A

FROM FRONT POWER DISTRIBUTION BOX

- --

--- 17

USE FID 301 --

a(DIAGRAM IOF5) FRONTPOWER DISTRIBUTION BOX

GRN/BRN OR RED/GRN

W/O PARK VENTILATION

W/PARK VENTILATION

Co RIGHTS EAT NTROLSWITCH

I I ! _I

BLOWER RELAY

HEADLIGHT/ FOGLIGHTCLEANING MODULE (SPA) (CANADA)

RED/YEL FRONT FROM FOG L LIGHT RELAY (DIAGRAM 1OF5)~111

PARKHEATING VENTILATION RELAYBOX

FROM FRONTPOWER DISTRIBUTION BOX (DIAGRAMIOF5)

RED

I I I

FROM FRONT POWER DISTRIBUTIONBOX (DIAGRAM10F5) FUSE " AUXILIARY PUSEBOX F47

FUSE F4B 401

FROM LOW BEAM M LIG HT RELAY (DIAGRAMlOFS)

- -

15A 7.SA L7 .SA --------------------4 2

YEL/RED OR YEL/BLU

RED/GRY/ YEL

W/OCCM

HIGHSPEED RELAY (1995)

I ON BOARD COMPUTER (1994)

ANTI-THEFT CONTROLMODULF

HORN RELAY

LEFI FOG LIGHT

FOGLIGHT

YEL

,FRONTPOWER DISTRIBUTION BOX

i5_A LI _____________I_ J

RED/I GRN

I- -

RELAY MODULE

L _J

BLOWER RELAY

RED

LEFTSEAT CONTROLSWITCH

INSTRUMENT CLUSTER

YELIGRY OR YEL/GRN

W/CCM

I I

LEFTLOW BEAM HEADLIGHT

I I CHECKCONTROL MODULE

FROM FRONTPOWER DISTRIBUTION BOX (DIAGRAM 1 OF5) CANADA FIR FRONTPOWER "M DISTRIBUTION BOX (DIAGRAM 1 OF5)

RED

131

I I I_ _ I

SUNROOF CONTROL ASSEMBLY

HIGH SPEED RELAY

COMPRESSOR CONTROL RELAY

REARFOG LIGHTSWITCH

YEL/BLK

FROM FRONTFOG LIGHT RELAY (DIAGRAM 1 OF 5)

FROM HIGH BEAM LIGHT RELAY X (DIAGRAM 1 OF 5)

RIGHTHIGH BEAMLIGHT

RED/WHT

LEFTHIGH BEAMLIGHT

W/O CCM

RIGHTLOW BEAM HEADLIGHT

ELECTRICAL WIRING DIAGRAMS

ELE-14

Power Distribution

1996-97 Except 318ti (1 of 5) RED RED

RED

1997

S.JUMPSTART JUNCTION POINT RED

RED

---- 1998W/ENGINE COMPTMOUNTED BATTERY

1996 W/TRUNK MOUNTED BATTERY

I I

ENGINE CONTROL MODULE

1996&1997 3181, 3181 ., 3181 CONVERTIBLE

1996 W/ENGINE COMPTMOUNTED BATTERY

BATTERY

RED I

BtJUMPSTART JU NCTION POINT

1996W/TRUNK MOUNTED BATTERY

ENGINE CONTROL MODULE RELAY

1997

I I

DATA LINK CONNECTOR

TRANSMISSION CONTROL MODULE(EGS)

_RED RED

1996 W/ENGINE COMPTMOUNTED BATTERY

r ( I(

1996 WITRUNK MOUNTED BATTERY

(FUEL

Pump

( RELAY

Zj I

I I

2// \\ GRN/VIO / ~ ENGINE CONTROLS

-I

1997 C

GENERATOR

I I

STARTER

I I

FUSE LINK RED

TO FUSE F49 (DIAGRAM 2OF5)

~_I

I I

DATALINK CONNECTOR

ENGINE CONTROL MODULE

____

ENGINE CONTROL MODULE RELAY

I I

__ I I I I

r I

TRANSMISSION CONTROL MODULE(EGS)

_I I

I I

GRNIV

I I

1 FUEL

I I

-I

I I

-I

I I

ENGINE CONTROLS

BATTERY 1997 M3 & 328i .32811, 3281 CONVERTIBLE RED RED

REDMP

RED

[EH]RED

START JUNCTION POINT

FUSE LINK

f BATTERY

I I

261

ENGINE CONTROL MODULE

ENGINE CONTROL MODULE RELAY

CTION

I I

281

I I

TRANSMISSION CONTROL MOD ULE(EGS)

¢I

RED

POINT

DATALINK CONNECTOR

I 61

r /y I f

FUEL ( PUMP (RELAY

I I

I -I

I I

I -,

! _I I

GENERATOR

STARTER

i _I

SECONDARY AI-PUMP RELAY

zJ 02 _

GRN/VIO

ENGINE CONTROLS

1996 M3 & 3281 . 3281 . . 3281 CONY ERTIBLE 1996M3&3281,32811 . 3281 CONVERTIBLE

TOFRONT DISTRIBUTION BOX (DIAGRAM 20F 5)

1997 M3&3281,3281 ., 3281CONVERTIBLF

UNLOADER RELAY (1997)

B+ JUMP START JUNCTION POINT

.1 8r

I I

1898&1997 3181 .3181x, 3181CONVERTIBLE

ELECTRICAL

Power

1996-97

FROM BATTERY (DIAGRAM 1OF5)

WIRING

Except

318ti

FROM BATTERY (DIAGRAM 1OF5)

SECONDARY AIR PUMP RELAY (1997 328, M3)

RED 2

RED

FUSE F78 20A

I I

RED

,58

I I

AUXILIARY FUSEBOX

FUSE F49 15A _____

I I

--------_ -

I I

_-____________-___

I FRONTPOWER DISTRIBUTION BOX I

______

_____

; I I I

PUP, PUMP

TOFUSEF35 (DIAGRAM50F5)

TO FUSE F20 (DIAGRAM 40F5)

I I

TOFUSEFS (DIAGRAM5OFS)

____-____

FUSE F40

68 O_

~,997

I i

I_I RIGHTSEAT CONTROL SWITCH

! _I LEFTSEAT LUMBAR SWITCH

I I

i I

! _I LEFT SEAT CONTROL SWITCH

I --

----------

l. 1' I

4 i I

WIPERI WASHER MODULE (1997)

1 I

,7 FUSE F61

L-1 UNLOADER RELAY

HEADLIGHT/ FOGLIGHT CLEANING MODULE(SPA) (1998)

18 O

I I

-I

I I

RELAY MODULE

ELECTRONICS SOOY CONTROL MODULE

___ FRONTPOWER Ir I FUSE-1 DISTRIBUTION BOX I F39 I

_5_j

1 I

! _I HIGHBPEED RELAY (328,M3)

1 I

! _I COMPRESSOR CONTROL RELAY

LOW I BEAM I LIGHT RELAY

I I

1998 CANADA

SNOTUSEO

VE'

_ ____ FUSE F-O---_ 7.SA

m h

O r

88975

IFRONT ,GWER DISTRIBUTION BOX FUSE

7 .SA f2-_-_____________ 18

FUSE

15A tOA--------P7_F17 10

to _ ~,99fi CANADA

BODVELECTRONICS CONTROL MODULE(ZKEIV)

FUSE

FUSE FUSE I F12 ] FIl 7 .SA------7.5=~

4 VEL/RED OR VEL/BLU W/OCCM

2 YEL/GRY~ OR YELIGRN W/CCM

2 I

RIGHTHIGH BEAM LIGHT

I _I HIGH SPEED RELAY (318)

RED t

I_' TOFUSEF47 (DIAGRAM 40F5) VEL/B17 RED/WH ; RED/YELL

1 I

--t ~F FRONT I /J I FOG I LIGHT I ( RELAY If _ZJ t-~ I

HIGH BEAM LIGHT RELAY

AUXILIARY

8 i

FUSE I FUSE BOX F68 I 40=,

-----------------III- -------____-__--------

REDS

6 i I

COMFORT RELAY (1997)

530A___

FRONTPOWER FUSE I DISTRIBUTIONBOX F19 I -

---

303-A-__

-II

USE 4

FUSE FUSE

.1c

fi~e~

______

FUSE F3

A___

17 FUSE F74

¢I

5 5 __ _ _ l7_~I_

FUSE F5 I 30A I __ 3_A_____-___

SUNROOF CONTROL ASSEMBLY

-__---__-4-----_--

TO IGNITION SWITCH (DIAGRAM 30F5)

1 r I

5 FUSE FUSE F1 F13 30A5

2 O >

TO FUSE FS (DIAGRAMSOF5) (1997)

____

~--,997

I I

30A CONVERTTIBLE TOPCONTROL MODULE (1997328)

---------_

2 I I

ELE-15

Distribution

FROM FUEL PUMP RELAY (DIAGRAM 10F5)

T .E . ,1 J~

DIAGRAMS

LEFTHIGH BEAM LIGHT

FO.

'~ LIGHT

W/OCCM

' e

EDQLIGHT

W/CCM

I -I INSTRUMENT CLUSTER

I I

r I

I _I REAR FOG LIGHTSWITCH

I _I LEFT LOW BEAM HEADLIGHT

I _ __ __-- _~ CHECK CONTROL MODULE

I _I RIGHT LOW BEAM HEADLIGHT

ELE-16

ELECTRICAL WIRING DIAGRAMS

Power Distribution

1996-97 Except 318ti (3 of 5) FROM FRONT POWER r< DISTRIBUTION BOX (DIAGRAM 2OF5)

___

______________

-------- _--------------------_ _ _-_-__----------START START OFF OFF

I OFF

=OC---U-

I SWITCH

START

____CC_CC--R=N-

-_-_---_-__-ACC--RU=

I IGNITION

START

CC-PUN

TO FUSE F16 yDIAGRAM 4 OF 5) 70 FU SEF28 (DIAGRAM 4OF5)

GRN

NOTUSED

I I

ENGINECONTROL No DULE(DME)

I I

UN LOADER RELAY

F-, I I

INSTRUMENT CLUSTER

_ °

----M FUSE 1'44

'________________________________

231

I I

WIPER/ WASHER MODULE

I I

WIPER/ WASHER MODULE (1996 CANADA)

.+ .

1 GLOVE BOX LIGHT

-) RADIO

I I

MI LEF7MAKEUP PROFLIGHT

TWIN RELAY MODULE (1996 CANADA)

CONVERTIBLETOP CONTROLMODULE

FROMFISE 141 ---(DIAGRAM 30F5)

I I

TELEPHONE TRANSCEIVER (1996)

51 .N+

------TO 1111111 (DIAGRAM 3 OF5)

~ FUSE F43

WASHER PUMP

CE TER CONSOLE TELEPHONE CONNECTOR (1987)

.+. I i

SEAT OCCUPANCY DETECTOR (199fi)

SWITCH SPATIALSOUND

. I 1

SEAT OCCUPANCY DETECTOR (1997)

RIGHTSIDE IMPACT SENSOR (1997)

LEFT SIDE IMPACT SENSOR (1997)

1 1 J

FRONT DOME/ MAPLIGHT ASSEMBLY

2 1 J

COMPUTER ON-BOAR

ANTI-THEFT CONTROLMODULE

88978

RIGHTMAKEUP MIRROR LIGHT

FUSE F45 7 .5A--______________-________________-______

WIPER RELAY (1996)

WIPER MOTOR RELAY (1998)

STARTER IMMOBILIZATION SWITCH (1997)

F -,

TRANSMITTER MODULE

INSTRUMENT CLUSTER

I -

BRAKELIGHT SWITCH

1 1

SRS CONTROL MODULE

ROLLOVER SENSOR

I I

LUG AGE COMPARTMENT TELEPHONE CONNECTOR (1997)

' S___

CRUISECONTROL MODULE

1),

1 1

FRONTPOWER DISTRIBUTIONBOX 1 I

FUSE F4fi 32Y

REAR INTERIOR

________--_--_________________-_----------------

I i F -, I-

CHECK CONTROL MODULE

21 J

30Y

. I 1

L-1 HORN RELAY

FRONTPOWER IDISDISTRIBUTION BOX I

USE 1' 42

5A _________________

-I

INSTRUMENT CLUSTER (1996) --

. 2_ I

I I

BLOWERRELAY

I I

( I

ELECTRONIC IMMOBLIZER CONTROL MODULE (EWS11)

CRUISECONTROL SWITCH

0 TALINK CONNECTOR TRANSMITTER MODULE (1996)

ELECTRICAL WIRING DIAGRAMS

ELE-17

Power Distribution

1996-97 Except 318ti (4 of 5) FROM1~ FRONT P. DISTRIBUTION BO X (DIAGRAM 2 OF 5)

RED

FROM IGNITION SWITCH (DIAGRAM 3 OF 5)

SRN

FUSE F20 30A

-_______-___ ~

.FN/N OR . RED/GR 1997 OR 1DSSW/OPARK VENTILATION

L -I

88989

5 __~

REO/GRY/ YEL

iml

_1 FE7 I E

AUXILIARY FUSE BOX

_=J

_1S96

1-1 I

COMPRESSOR CONTROL RELAY

I __

1-1 I

I I

NORMAL SPEED RELAY

I I I __I

HIGH SPEED RELAY

CONANTI-THEFT TROLMODULE

HORN RELAY

I I

BLOWER RELAY

GRN 7

L-1

THERMOSTAT

LIGHT SWITCH

L-1

HIGH BEAM LIGHT RELAY

!_I

WATER COMBINATION VALVE SWITCH ASSEMBLY

REVERSING LIGHTSWITCH

L-1

INSTRUMENT CLUSTER

L -I

REAR DEFOGGER RELAY

AUTOMATIC TRANSMISSION RANGESWITCH

L-1

MULTIFUNCTION CLOCK

L-1

UNLOADER RELAY

L-1

PROGRAM SWITCH

SLIPCONTROL MODULE (ABS) (1996)

L-1 LIGHT SWITCH

THROTTLE FLAP HEATER (1996)

SERVOTRONIC CONTROL MODULE (1996)

! _I AEC SWITCH

INSTRUMENT CLUSTER

L-1

ABSSLIP CONTROL MODULE

1____l

L -1

PARK HEATING VENTILATION RELAY BOX

MIRROR CONTROL SWITCH

AUTOMATIC CLIMATE CONTROL MODULE

BLOWER RELAY

--_____-___

AUTOMATIC TRANSMISSION RANGE S W ITCH

I I

- - - - FRONT POWER DISTRIBUTION BOX FUSE ,IS

FUSE F28 5A

11998W/PARK VENTILATION

FROM IGNITION SWITCH (DIAGRAM 30F5)

FROM(~ RED FRONTPOWER II JDISTRIBUTION BOX (DIAGRAM 2 OF 5)

GRN

-------------

FROM IGNITION SWITCH (DIAGRAM 3 OF 5)

L-1

ASS RELAY

ELECTRICAL WIRING DIAGRAMS

ELE-18

Power Distribution

1996-97 Except 318ti (5 of 5) RED -- - - I .Sl O I I

NLY ------------------------------------------

FUSE Ffi 20A

FROM RED ~H FRONTPOWER DISTRIBUTION BOX jl (DIAGRAM2OF5)

FROM FRONT POWER DISTRIBUTION BOX (DIAGRAM2OF5)

1995ONLY

FUSE FB 15A

FUSE F7 SA

FUSE F9 20A '

1 Tw

q W/HIFI , TEN SPEAKER SYSTEM

I i I

L-1 REAR DEFOGGER RELAY

I I

! _I LEFT DOOR LOCK SWITCH

I I

! _I RIGHT DOOR LOCK SWITCH

F',

! _l LEFT DOOR LOCK MOTOR

F', I

! _I RIGHT DOOR LOCK MOTOR

! _I TRUNK LOCK MOTOR

I I

F',

L-1 CONVERTIBLE TOPCONTROL MODULE

F', I I

!-IL-1 TRUNK LID MICROSWITCH

TRUNK LID RELAY

I - i I I

I I

L-1 CONVERTIBLE TOPSTORAGE LIDLOCK MOTOR

i I

I -

L-1 L-1 BODY CENTRAL ELECTRONICS LCOKING CONTROL SWITCH MODULE (1996)

DISTRIBUTION BOX

FUSE F10 I 30A I

L-1 RADIO

L-1 ASS CONTROL MODULE

32 B, M3 WIASC

318 IN ABC

'7-

I i l i I

L-1 HORN RELAY

ALL - I WIASS I

1-1 HIFI AMPLIFIER

I I

!-IL-1 SLIP CONTROL MODULE

ABS RELAY

I I

L-1 ABS PUMP MOTOR RELAY

_________________________________________-]PRONTPOWER I FUSE F31 SA

I I I L

tFUSE F32 30A

------------

__ .__

FROM 0 FUSEF34 (DIAGRAM 5OF5)

. . . . JFUSE 133 t 0A

-----------

____

I DISTRIBUTION BOX I I I

----------

RED/YEL FRONT CIGAR LIGHTER

I I I

F -, I I

___I L-1 WATER AUTOMATIC VALVE CLIMATE AS SSEMBLY CONTROL MODULE

FROM FRONTPOWER G DISTRIBUTIONBOX (DIAGRAM 2 OF 5) I r I I

TO FUSE F 33 (DIAGRAM 5 OF5)

F -, I I

I-_I ELECTRONIC IM ILIZER CONTROL MOB MODULE

L-1 CHIME MODULE

I I

L-1 ON-BOARD COMPUTER (1997)

I I

L-1 L-1 MULTIINSTRUMENT FUNCTION CLUSTER CLOCK

I I

I _I CHARGING SOCKET

FUSE F35

FUSE F36

FUSE F3T

FUSE F3W

25----------

______

_____

FRONTPOWER I DISTRIBUTION I I

CANADA

L-1 HAZARD FLASHER RELAY

_I CRASH CONTROL MODULE WW983

I I

CENTER CONSOLE TEL PHONE CONNECTOR

L-1 IGNITION SWITCH

I I

I -i I I

I I

RED

FUSE F34

I -i I I

OBD11 CONNECTOR

L-1 LIGHT SWITCH

I I

L-1 CONVERTIBLE TO PCoNTROL MODULE (1996)

USA

328, M3 WIASC

315 W/ASC

ALL W/ABS

I I

1"! I I

I I

I -j I I

1'l--I I I

1 - -i I I

! _I BOO Y ELECTRONICS CONTROL MODULE (ZKEIV)

1__ j WIPER RELAY

1__ J WIPER/ WASHER MODULE

1__ j LIGHT SWITCH (USA)

1__ j ABS PUMP MOTOR RELAY

SLIP CONTROL MODULE

I I

BODY ELECTRONICS CONTROL MODULE (ZKEIV)

I I

1- 1 ABS CONTROL MODULE

I I

~ 1

II I I TRUNK LIGHT

I I

TELEPHONE TRANSCEIVER (1996)

I I

CD CHANGER

11 III..

I LUGGAGE I COMPARTMEN ELEPHONE I-_I CONNECTOR FRONT DOME/MAP LIGHT ASSEMBLY I

ELECTRICAL WIRING DIAGRAMS

ELE-19

Power Distribution

1998 Except 318ti (1 of 5) BtJUMPSTART JUNCTION POINT

_RED RED

FUSE LINK 80A

! ___I

ENGINE CONTROL MODULE

ENGINE CONTROL MODULE RELAY

! _I

DATALINK CONNECTOR

TRANSMISSION CONTROL _ MODULE(EGS)

I ( (_ sJ (

FUEL PUMP (RELAY

!_I 1

UNLOADRELAY

! _I I

STARTER

! _I

GENERATOR

BATTERY

15~X 1DD16 F

USE IB T15A

I I

- FRONT POWER I DISTRIBUTION BOX I

161 X111010

FUEL PUMP

BtJUMPSTART JUNCTION POINT

RED _ RED

FUSE LINK BOA

14j, DATA LINK CONNECTOR

I I

261

___I

ENGINE CONTROL MODULE RELAY

I ! _I

ENGINE CONTROL MODULE

261

I ! _I

TRANSMISSION CONTROL MODULE

r I

f _

f !

FUSE (, F4 . 2CA Z

I I

27X19564

I 1 -

(

Pmp FUEL (RELAY

CONVERTIBLE TOPCONTROL MODULE

!_I I

STARTER

I ! _I

GENERATOR

I ! _I

UNLOADRELAY

51X 10016 - AUXILIARY I FUSE BOX I

I I 1 -

FRONTPOWER I DISTRIBUTIONBOX I 8= -- I

FUSE F'A

61X 10816

I 1 -

104370

FUEL PUMP

¢ 3231CONVERTIBLE, 3231 . . 3281, 3281C ONVERTIBLE, 32815 . M3

¢ _" 3181

TOFRONT DISTRIBUTION BOX (DIAGRAM 2 OF 5)

ELE-20

ELECTRICAL WIRING DIAGRAMS

Power Distribution

1998 Except 318ti (2 of 5) FROM JUMPSTART JUNCTION POINT (DIAGRAM 1 OF 5)

_-_____________________

I--

SEIOAI CON RV AIRP UMP RELAY

--_-------__----------__

- 17 X1901fi FRONT - - _ - - - POWER `I FUSE 71~ FUSE I DISTRIBUTION BOX J̀ F14 (7 FlS I } 30A T 3DA

FUSE Fl 30A Q IX 1n015

_ -

1¢ (X10018 O

BI I

X10411 11

_________

FOF6 =0 30q

30A

RED/V EL I X-

51 I

14),

3.4.

I I j _I

I I

RIGHT FRONTS-7 CONTROL SWITCH

---- -

1 _I LEFT FRONTSEAT LUMBAR SWITCH

6),

F -I I

I I

_I LEFT FRONTSEAT CONTROL SWITCH

1 _I WIPER/ WASHER MODULE

REAR DEFOGGER RELAY

it ~

UNLOADER RELAY

1~X15xn

X1491& I

-5-

FUS F48E~~uaeovn

40A

6,1

I I

RELAY MODULE

(F39EJUInInInuI~unnun

/F41E 3-q==-

X144]'.

21~ ---

16---4,c

- -

-5

-_ -\X10018

15 I

BODY ELECTRONICS CONTROL MODULE

SUNROOF CONTROL ASSEMBLY

FRONTPOWER DISTRIBUTION 80X

X15RH

X1441fl

F -I I

I I

HIGHSPEED RELAY (323,328, M3)

COMPRESSOR CONTROL RELAY

HIGHSPEED RELAY (318)

---------f_-------------_-___--------------_----

I TO FUSE F47 (DIAGRAM 4 OF 5)

----

2T RED/VELI

USED) 9 X14016 ____________--

4 REO/WHT

I FRONT FOG I LIGHT RELAY _I

L --

t FE .T` . ./

LEFT FOGLIGHT

RIGHT FOG LIGHT

y 2

USED) X10035

_-_______-_________5~ _________-_-___-____--t__

I I

FUSE F30 7 .SA 18

X 7003fi

i _I INSTRUMENT CLUSTER

I _I RIG THIGH BE AMLIGHT

IFFONTP-ER DISTRIBUTION BOX

FUSE FUSE I FUSE F29 F12 F11 7 .5A = _ _ _ _ _ _ __ 5 - 4 X]4439. 2(X19416 YELIRED (OR I YEL/BLU)

W/OCCM

21 I I

LOW BEAM LIGHT

YELt

-I BODYELECTRONICS CONTROL MODULE (ZKE IV) 104371

RED/W HT

FUSE F11 15A (W/0 CCM) 7 .5A(W/CCM) _ _ _ _ _ _ _ _ _ _ _ _ _ - - - _ _ _ _ _ _ _ _ 1~IX 10016 20I

I I

HIGH BEAM (LIGHT (RELAY

21 I I

I__I LEFTHIGH BEAMLIGHT

1 --i I I I-_I RIGHT LOWBEAM HEADLIGHT

YEL/GRY (OR YEL/GRN)

W/CCM

151

W/CCM

8j,

r --------i I I I

CHECKCONTROL MODULE

2 1 --i I I I _I LEFT LOWBEAM HEADLIGHT

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

WIRING

ELECTRICAL

Power

1998

ELE-21

DIAGRAMS

Distribution

Except

318ti

FROMFRONTPOWER DISTRIBUTION BOX (DIAGRAM 2 OF 5)

I IGNITION SWITCH

I OFF

START ACC-__U-

ACC " __U_

_____________ _

START

OFF

_____

C_-

OFF

_____

START

C____

TOFUSEF28 (DIAL RAM 4 OF 5)

GRN

TOFUSEF16 (DIAGRAM 4 OF 5)

GRN NOTUSED

GRN

TOFUSEF24 (DIAGRAM 4 OF 5)

I I

(2 .8 L) 1 . 9 L(

1 I

I I

ENGINECONTROL No DULE(DME)

I I I

START

OFF

8 _

I I

I I _I

I I

UNLOADER RELAY

FUSE F44 154 v__-----__---------

I I I I L-1

INSTRUMENT CLUSTER

ELECTRONIC IMMOBLIZER CONTROL MODULE IF-")

UNCOUPLING DIODE

I I

BLOWER RELAY

-1 I I I _I

HORN RELAY

231X7Oat8 --- - - ------TOFUSEF45 'DIAGRAM S CPS) " FUSE

0259

FUSE

FRONT POWER I DISTRIBUTION BOX

a-- _ ---____--aaa-r ==== =---~, . 2B

\ _'

GLOVEBOX LIGHT

I I

I--1

I-

WIPERI WASHER MODULE

I I LEFT MAKEUP MIPROFLIGHT

RADIO

I I

I I I

CONSOLE TELEPHONE CONNECTOR

I I

SPATIAL SOUND RELAY

TOP H FI SWTCH I

51 4

I 1

BODYELECTRONICS CONTROL MODULE (ZKE IV)

Pump

WASHER

I I

CONVERTIBLETOP CONTROLMODULE

I I

LEFT FRONT SEATBELT SWITCH

I I

I I ANTITHEFT T CONTROLMODULE

FRONTDOME/ MAPLIGHT ASSEMBLY

51 1 I I

5; 2 I

RIGHT FRONT SEATBELT SWITCH

SEAT OCCUPANCY DETECTOR

I I

RIGHT MAKEUP MIRRORLIGHT

FIGHT SIDE IMPACT SENSOR

I I

LEFT REAR INTERIOR

_____________________________ _ ______ FROM FUSE F43 --(OIAGRAM30F5) J - - - - - FUSE FUSE 146 F45 7 .5- _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

LEFT SIDE IMPACT SENSOR

I I

ROLLOVER SENSOR

I I

LUGGAGE COMPARTMENT TELEPHONE CONNECTOR

RIGHT FEAR INTERIOR

FRONTPOWER I DISTRIBUTION BOX II

ON-BOARD COMPUTER MODULE 10437 2

I I

CHECK CONTROL MODULE

I I

STARTER IMMOBILIZATION SWITCH

TRANSMITTER MODULE

I f

INSTRUMENT CLUSTER

BRAKE LISHT SWITCH

CRUISE CONTROL MODULE

CRUISE CONTROL SWITCH

SUPPLEMENTAL RESTRAINT SYSTEM CONTROL MODULE

16 I I

DATALINK CONNECTOR

GEN/YELT L 2OF5) BOY% OM~ GRNI VELCONTROL (DIAGRAM CONTROL WIO AUTO CLIMATE MIRRORELECTRICAL 21"~e GRNI 1 VEL HEATER GRNJET_________ SLOWER RELAY SWITCH IGNITION i I (DIAGRAM H CLUSTER TRANSMISSION AUTOMATIC F24 WIRING '1llZ I___________________-__-_______________,FRONTPOWER DEFOGGED RUNNING FUSE DAYTIME i --Except _________ -- FUNCTION DIAGRAMS _CLOCK -i 5) Distribution ----_hRRICC G 318ti 11j EGS)RELAY 5AI NORMAL ICOMPUTER F-, (4 SPEED RELAY DISTRIBUTION _of POWER5) I RELAY SWITCH BOX SPEED HIGH SWITCH _II 5-PROGRAM SWITCHMODULE/ iBOX F SWITCH PED NTROLMODULE i -I C y__J X102s0 F47 _jCONTROL III DISTRIBUTION DISTRIBUTIONBO% I HORNRELAY AUXILIARY I I BOXRELAYI

ELE-22 Power 1998 FP FRONTPOWER DISTRIBUTION (DIAGRAM

PED

FROM SWITCH (DIAGRAM30F5)

GRN

0 GRNIBRR RED/GORN

r-______ I FUSEF23 K I 40F5) I I L L_______

FROM FRONTPOWER DISTRIBUTION (DIAGRAM20F5)

__11 _ FUSE

I (

IFUSEBO%

121K1D2=D i

S I I I I PARKHEATING VENTILATION RELAYBOX (W/PARK VENTILATION) FROMIGNITION SWITCH (DIAGRAM 30F5)

GRN

15X .1901Z 11IXmlfi FRONT, FUSE USE I Fze 1J,F1s 5A i .X002XgOS 11

FUSE Fzo

FPOMIGNI710N SWITCH (DIAGRAM OF

I I

41 I I I COMPRESSOR CONTROL RELAY

RANGESWITCH

el I

I Co ANTI-THEFT

X7002B FUSE F24 I

101

FUSE F25 5A

12 =1

FUSE F2B 10A _---_--

________-IFRONTPOWER I I FUSE F27 SA 141X10012

GRN/BL

ROLLOVER SENSOR

LIGHT SWITCH

SWITCH THERMOSWITCH I I I

GRNIBLU AUTOWl CLIMATE CONTROL GRN/I VEL

FUSEFROM K 40F5)

AUTOMATIC TRANSMISSION RANGE

INSTRUMENT CLUSTER

USE F23 5A-vvv--vv-~vv--cvvvvcv- F22 61 41 W/OASC

" _-__--_---- . " ----+

I FUSE F21 5A___ I zIx1oD17 GRNI BLU/ VEL

WIASC

I I I I II I-I I I I I I I I I I I AUTOMATIC WATER CLIMATE THERMOSTAT ASSEMBLY VALVE COMBINATION INSTRUMENT MODULE 10437 3 I

REVERSING LIGHTSWITCH (W/O

LAMPS MODULE

REAR RELAY

I I

MULTI-

I I I I UNLOADER

I II I ! ON-BOARDI MODULE

I i I I ! LIGHT

II I L-1 ABSCONTROL HYDRAULIC UNIT

I I I LAS

I I L-1 SLIP MODULE

I I L-1 ASS

ELECTRICAL

WIRING

DIAGRAMS

ELE-23

Power Distribution

1998 Except 318ti (5 of 5) FP OM 1~ RED FRONTPOWERIEJ ._--~ DISTRIBUTION BOX (DIAGRAM 20F5) 1 X1 D 0 +6

I II

FUSE F7 5A

FUSE FS 15A

L ti, --_-------_---__-_---------

I I

L -I

LEFT FRONT DOOR LOCK SWITCH

B,~

I I

L -I

LEFT FRONT DOOR LOCK MOTOR

L -I

RIGHT FRONT DOOR LOCK SWITCH

RIGHT FRONT DOOR LOCK MOTOR

L -I

TRUNK LOCK MOTOR

L -I

CONVERTIBLE TOPCONTROL MODULE

1 - 7

L-1

L -I

TRUNK LID MICROSWITCH

TRUNK LID RELAY

I --,

L -I

L-I

CONVERTIBLE CENTRAL TOP LCOKING STORAGE SWITCH LIDLO MOTOR

FUSE 531 5A

,FRONTPOWER IDISTRIBUTIONBOX

I I

20 XSD0L5

I I

RADIO

I --,

1 -- I --i

1 --

L -I

! _I ! _I

L -I

L-11-1

HORN RELAY

HIFI AMPLIFIER

ASS CONTROL MODULE HYDRAULIC UNIT

I I

SLIP CONTROL MODULE

PBS RELAY

ASS PUMP MOTOR RELAY

_____________-I FRONTPOWER FROM I DISTRIBUTION BOX FUSEF34 FUS~ (DIAGRAM I F33 50F5/, II ,OA

I I I

FUSE F10 30A

F -,

FUSE FO 20A

,61

_ _ _ _ _ _ _ _ _ _ __

FUSE F32 30A

____--__________________J-________J

REDIYEL

I II

I I II I

I I,

I I

L -I

WATER AUTOMATIC VALVE CLIMATE ASSSEMBLY CONTROL MODULE

I I

TO FUSEF33 (DIAGRAM

ELECTRONIC IM MOBILIZER CONTROL MODULE

FROM FRONT PO WE R DISTRIBUTION BOX (DIAGRAM 2 OF 5)

I II

CHIME MODULE

I II

ON-BOARD COMPUTER MODULE

I ',

I II

I I

MULTIINSTRUMENT FUNCTION CLUSTER CLOCK

I -I I 1 rtl ml

, s1

+I I I

n _,,,,,,

OBDII CONNECTOR

I I

CENTER CONSOLE TELEPHONE CONNECTOR

I LIGHT SWITCH

0203 i

CHARGING SOCKET

IGNITION SWITCH

RED

FUSE F34

11X10018

FUSE F35

loll,

FUSE F38 30A

FUSE F37 lo A

__] FUSE F38

FRONTPOWER I DISTRIBUTION BOX I I

12 I I

! _I BODY ELECTRONICS CONTROL MODULE (ZKE IV)

CRASH CONTROL MODULE 104374

HAZARD FLASHER RELAY

BODY ELECTRONICS CONTROL MODULE (ZKEIV)

WIPER/ WASHER MODULE

LIGHT SWITCH

ABS PUMP MOTOR RELAY

SLIP CONTROL MODULE

ASS CONTROL MODULE/ HYDRAULIC UNIT

I I

I _I TRUNK LIGHT

I I

I _I CD CHANGER

I LUGGAGE ( COMPARTMENT TELEPHONE I _I CONNECTOR FRONT DOME/MAP LIGHT ASSEMBLY I I

ELECTRICAL WIRING DIAGRAMS

ELE-24

Power Distribution 1995-96 318ti (1 of 5)

FUSIBLE LINK

BiJUNCTION POINT

REO

BATTERY

2fi1

281

I I

ENGINE CONTROL MODULE

I I

DATA LINK CONNECTOR

TRANSMISSION CONTROL MODULE (EGS)

II' 81 81 B1

(

FU E L PUP M

I RELAY

ENGINECONTROL MODULERELAY

RED

2 O

I I

GENERATOR

I I

STARTER

GRNIVIO

__ _ _ _ _ .- __ _ _ _ -_ _ _ _ _ - - - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ __ __ __ __ _ _ __ _ _ - _ -

F18 FUSE 15A _____________-_________ 3

JF2 FUSE ~. 15A ___________ 4v

RED I

TO FUSE F5 (DIAGRAMSOF5)

TO FUSEF40 (DIAGRAMSOF5)

TOFUSEF3 (DIAGRAM 5 OF 5)

I I I

I I

FUEL PUMP

TO IGNITION SWITCH (DIAGRAM20F5)

-14

RED

TOFUSEF20 (DIAGRAM20F5)

RED

TOFUSEF39 (DIAGRAM 50F5)

;

RED RED

RED

TO FUSE F8 (DIAGRAM40F5)

G D

RED

2 3

F I I

LOW

GHT f--i ( RELAY

I FRONT FOG I L GHT RELAY

RED/WHT

5 NOTUSED

INSTRUMENT CLUSTER

TO FUSE FII (DIAGRAM5OF5)

8887 1

TO FUSE FiS (DIAGRAM 5OF5)

_____________

I 15IGH EAM I LIGHT ~j RELAY

I FRONTPOWER DIS7RIBUTION80X

(NOTUSED)

RED

-1

------------------

TO FUSE F29 (DIAGRAM 5OF5)

BODYELECTRONICS CONTROL MODULE (ZKEIV)

BODY ELECTRONICS CONTROL MODULE (ZKEIV)

RELAY MODULE

TO COMFORT RELAY (DIAGRAMSOF5)

ELECTRICAL WIRING DIAGRAMS

ELE-25

Power Distribution 1995-96 318ti (2 of 5)

a ---

FROMFRONTPOWER DISTRIBUTION BOX (DIAGRAM 1 OF 5)

----__-~~~___-

--_--_- .-- .--

_ _ -O__/'_S_ _ __ _ I I --- _- --- --- --- _ _ -START __OFF

OFF

__ START

TA RT

RUN

ACC

RUN

OF F

ACC

RUN 21

BLKIVELI

IGNITION

I SWITCH START I

GRN

TO FUSE F16 (DIAGRAM 3 OF 5) TOPUSEF28 (DIAGRAM 3 OF 5)

TOFUSEF24 (DIAGRAM 30F5)

GRN

NOTUSED

CONTROL MODILLE(EWS11)

15),

INSTRUMENT CLUSTER INSTRUMENT CLUSTER

BLOWER RELAY

561

I I

-I

ENGINECONTROL No DULE(DME)

~ -I

I I

IGNITION COIL#1

II II L -I

IGNITION coILN2

II II L -I

HORN RELAY

D O

TO FUSE F45 (DIAGRAM 3OF5)

TOFUSEF46 (DIAGRAM3OF5)

IGNITION COI-

II II L -I

IGNITION CO L .4

VIO

-_ ~

1 I

8IL

BODYELECTRONICS CONTROL MODULE (ZXE 11)

-----

42E 7 .5A

_--------_---__---

43E ----____-__--SA_---_---- ------

F44E 15A --I

I DRSTRIBUWONBOX

SRSCONTROL MODULE 23

-I

BODY ELECTRONICS CONTROLMODULE (ZKE IV)

iI I-I L -I

DRIVER'SMAKEUP MIRRORLIGHT 88873

I--, I I L-1

PASSENGER'S MAKEUP MI RRORLIGHT

II 1I L -I

TELEPHONE TRANSCEIVER

II iI L-1

FRONTDOME/ MAP LIGHT ASSEMBLY

II iI L-1

GLOVEBOX LIGHT

ANTI-THEFT CONTROL MODULE

WIPERIWASHER MODULE

I-I 1I L -I

WIPERIWASHER MODULE

II - iI L-1

WASHERPUMP

WIPER/WASHER SWITCH

II 1I L -I RADIO

I-I 1I L-1

RA010 RECEIVER

ELE-26

ELECTRICAL WIRING DIAGRAMS

Power Distribution 1995-96 318ti (3 of 5)

FROM IGNITION SWITCH (DIAGRAM2OFS)

PROMIGHITION SWITCH (DIAGRAM2OF5)

VIO

..11I~~ J FUSE . 45 1I75=

FROM IGNITION SWITCH (DIAGRAM 2OF5)

VIO

GRN

~N '4S FUSE ___________.-_-_--___-_____

15A

FUSE ___________-_______

I DISTRIBUTION BOX

5A6_

VIO/Y EL

VIOIYEL

I I

1-7

I I WIPER RELAY

TRANSMITTER MODULE (EWSII) (1998)

I I

0 GRN

15 _

_________ 11

101

1-- j BOARD COMPUTER

,6/

1-- l DIGITAL CLOCK

WIPERMOTOR RELAY

GRN

101

INSTRUMENT CLUSTER

OATALINK CONNECTOR (1996)

1--l

I _I BRAKE LIGHT SWITCH

I I

281

L -I CRUISE CONTROL MODULE

>--:

L-1 CRUISE CONTROL SWITCH

I FROMIGNITION SWITCH (DIAGRAM 2 OF 5)

! _I TRANSMITTER MODULE (EWSII) (

I I

1--i COMPRESSOR CONTROL RELAY

L -I NORMAL SPEED RELAY

)

L-1 HIGH SPEED RELAY

FRONTPOWER DISTRIBUTION BOX

___________________________________________-__________

I I I

FUSE ~ F28 5A I_ .. _________

FU F26BE 10A ________

FUSE F25 5A __________________

FUSE F26 10A ________________________

FUSE F27 5A -

F ,

AUTOMATIC TRANSMISSION RANGESWITCH

I i I I I _I

I I

121 fff~~~

JET HEATER THERMOSWITCH

MIRROR CONTROL SWITCH

I? - I

LIGHT SWITCH

REVERSING LIGHTSWITCH

i I

FOG LIGHT SWITCH

68874

I - i

AUTOMATIC TRANSMISSION RANGESWITCH

WIOEGSONlY-1

I _I INSTRUMENT CLUSTER

PROGRAM SWITCH

FUSE F F22 F23 5A 5A T_____________________________-_________X

F F21 SA Y ____ -

DATA LINK CONNECTOR

I-~i I I COMBINATION SWITCH

I I

INSTRUMENT CLUSTER

(- i I I

1 - ; I I

REAR DEFOGGER RELAY

LIGHT SWITCH

I I

v I

UNL0ADES RELAY

I i I I

I -Ii I I

I -1 i I I

I i I I

I I

SLIP CONTROL NO OULE(ASS)

FRESH AIR RECIRCULATION MOTOR

WATER VALVE ASSEMBLY

INKS CONTROL SWITCH

LIGHT SWITCH

I I

ASS SLIP CONTROL MODULE

I i I I ASS RELAY

ELECTRICAL WIRING DIAGRAMS

ELE-27

Power Distribution 1995-96 318ti (4 of 5)

FROM FRONT POWER DISTRIBUTION BOX (DIAGRAM 1 OF 5)

RED

I I I I

FUSE Ffi

FUSE F7

20A-___-_____________

5A___________________

,tv

I-

I-i I I

I- i I I

I-i I I

F -, I I

REAR DEFOGGER RELAY

DRIVER'S DOOR LOCK SWITCH

PASSENGER'S DOOR LOCK SWITCH

LEFT DOOR LOCK MOTOR

CENTRAL LOCKING SWITCH (1996)

RIGHT DOOR LOCK MOTOR

TRUNK LOCK MOTOR

BODY ELECTRONICS CONTROLMODULE (ZKEIV)

! _I

!_I

1-I

L-1

1 _I

L-1

FUSE F31 5A

I I

CONTROL MODULE (EWS 11)

20Y

I- i I I

I I

1=Y

I FUSE I F10 I 30A

FUSE FS 20A

USE FB A

22 I I

~ _i

BOARD COMPUTER

(

L-1

HIFI AMPLIFIER

FUSE F33 10A

FRONT -, CIGAR I LIGHTER 1

RED/WH

ABSRELAY

FROHTPOWER I DISTRIBUTION BOX I I

~ _I

DIGITAL CLOCK

INSTRUMENT CLUSTER

FROMFRONTPOWER D DISTRIBU710NBOX (DIAGRAM 1 OF5) _____________, _----1 I

RED

T-

L-1

RADIO

FUSE F32 30A

G203 I I I 1 L._______

HORN RELAY

FUSE 4 F3S 131 15A--___ T 25A-_-_____,~30A---_ J10A-___

(

I¢ I I I L-1

I I L-I LIGHT SWITCH

IGNITION SWITCH

I C I I L-1 I

FRONTDOMEi MAP LIGHT ASSEMBLY

F3 .

W1 RASH CONTROL MODULE RED/WH

F -, I I

FI I

CRASH CONTROL MODULE

HAZARD FLASHER RELAY

-I

8887 6

L-1

I I

1 D,L I I

BODY ELECTRONICS CONTROL MODULE (ZKE IV)

2),

I I

L-1 WIPER RELAY

I I

6j, I I

L_I

WIPER/ WASHER MODULE

I I

REO/W 121

11j,

F -, I I

I I

L-1 LIGHT SWITCH (USA)

ABSPUMP OTOF RELAY

TRUNK LIGHT ASSEMBLY

F -, I I CO CHANGER

al I I

BODY ELECTRONICS CONTROLMODULE (ZKE IV)

I 1

1s 1

TELEPHONE TRANSCEIVER

ELE-28

ELECTRICAL WIRING DIAGRAMS

Power Distribution 1995-96 318ti (5 of 5)

FROM FRONT POWER DITIONBOX (DIAGRAM IOFS)

~~ RED

191

FROM FRONT POWER ^ DISTRIIONBO)( (DIAGRAM 10F5)

FROM FRONT POWER D TIO (DIAGRAM 10F 5)5)

RED I 91

FROMFRONTPOWER 1~ RED DISTRIBUTION BOX I37~ (DIAGRAM 10F5)

RED 1 I91

5 J, D STRI6UTIONBOX

.30A-----------/~30A--------------l.30A-_--------------

30AE-~

I I

BLOWER RELAY

I {

I I

PASSENGER'SSEAT CONTROLSWITCH

DRIVER'SSEAT LUMBARSWITCH

I I

DRIVER'SSEAT CONTROLSWITCH

FROM FRONT FOG LIGHTRELAY (DIAGRAM IOF5)

I I HEADLIGHT[ FOOLIGHTCLEANING MODULE(SPA) (CANADA)

REAR/WIPER WASHER INTERVAL CONTROL MODULE

RED/YEL 1

FROMLOWBEAM ~ IM ~ YEL LIGHT RELAY (DIAGRAM 5OF5) V I --------------

RED AUXILIARY r ~ FUSE --------- ~ FUSE -1IFUSE80X F68 I EC7 L D--__________ 11-J

RED/I GRN

RED/GRV/ YEL

I I

~ I

HIGH SPEED RELAY

I I

ANTI-THEFT CONTROLMODULE

~ I

I I

I LEFT FOG LIGHT

HORN RELAY

FROMFRONTPOWER DISTRIBUTIONBOX (DIAGRAM IDES) 6 ,1

6 BLK/GRN

RIGHT FOG LIGHT

INSTRUMENT CLUSTER

RIGHT LOW BEAM HEADLIGHT

LEFT LOW BEAM HEADLIGHT

COMFORT RELAY

FROM HIGHRELAY BEAM /~ RED-HT LIGHT IK _ (DIAGRAM I OF5 ) I/

BODY -0- .--_J5--_---- ._-0-_---17 .5A---L_ Y .5---------_ ELECTRONICS 18 6 1 207 CONTROL (NOT USED) (NOT USED) MODULE

88878

FROMFRONTPOWER DISTRIBUTION BOX (DIAGRAM I OF 5)

2 RED/BLU

SUNROOF CONTROL ASSEMBLY

I I

COMPRESSOR CONTROL RELAY

islI

UNLOADER RELAY

7-5- .-----_

I87

I I

RIG THIGH BEAMLIGHT

LEFTHtGH BEAMLIGHT

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-29

Power Distribution 1997 318ti (1 of 3)

B,JUM START JUNCTION POINT

FUSE LINK RED

26 I

CONNECTOR

IRELAY

I 1--i UNLOADER RELAY

O -

I I

1- 7

1 -1

!_I __I !_I !_I

ENGINE CONTROL MODULE

ENGINE CONTROL MODULE RELAY

TRANSMISSION CONTROL MODULE(EGS)

GENERATOR

! _I STARTER

BATTERY 15 1 l~

__________________-______________

FUSE F18

! _

1-A________

_-------- FRONT POWER DISTRIBUTION BOX I

J FOLDING ROOF

SUNROOF ROOF

RED'

RE O

..+1+1+1/ .

COMFORT RELAY

FUEL PUMP

TO FUSE F6 (DIAGRAM 2 OF 3)

TO IGNITION SWITCH (DIAGRAM20F3)

TO FUSE F35 (DIAGRAM30F3)

TOFUSEF20 (DIAGRAM20F3)

TO FUSE FB (DIAGRAM30F3)

HIGH SPEED RELAY

UNLOADER RELAY

BOGY ELECTRONICS CONTROL MODULE

COMPRESSOR CONTROL RELAY

SUNROOF CONTROL ASSEMBLY

--_-_-_-------4-_-----0-----_-___--------0-----RED HIGH BEAM I LIGHT RELAY

I Ir

I I

22 REO/WHT

~AUXILIARV FUSE BOX FUSE 5A

r I I

¢I

RED/ BRNIYELI

I- 1

I --,

BODY ELECTRONICS CONTROL IV) MODULE (ZKE 80135

ANTI-THEFT CONTROLMODULE

I I

2j,

I _ _I RIGHTHIGH BEAM LIGHT

(LOW BEAM -~

( LIGHT I RELAY

2 YEL

USE

I I

I -I LEFT HIGH BEAMLIGHT

I I

15A

FUSE

___

7-5 -__

RED( BRNIYEL

1aJ

T30A-___-____ .______,_

-_1~?6____

2),

IFRONTPOWER DISTRIBUTION BOX

IFusE FUSE 1̀J

FUSE

~75A

I LGHT I RELAY

RED/YEL

1J~ I

(FRONT

2 I I

I _I WIPERl WASHER MODULE

I I

i_ -I REARWIPER1 WASHER CONTROL MODULE

FOGEFGHT

FOG LIGHT_

)

I I

I _I INSTRUMENT CLUSTER

I I

I _I RIGHT LOW BEAM HEADLIGHT

I I

I i

L_I LEFT LO WBEAM HEADLIGHT

ELE-30

ELECTRICAL WIRING DIAGRAMS

Power Distribution 1997 318ti (2 of 3)

FROM FRONT POWER DISTRIBUTION BOX (DIAGRAM 1 0F3)

I I OFF I I ACC

_ -- - - - - - - - -_ _ _ _ _ _ _ _ _ _ _ __ _ _ START OFF -R=_

ACC-

____-____-______________

IGNITION I SWITCH

_ _ _ _ _ START O FF RUN

ACC

START I I

-_-C~

TO FUSE F24 (DIAGRAM 30F 3)

:,),

I I

________ FUSE F28 5A

FUSE F1S 5A

--I AUTOMATIC TRANSMISSION RANGESWITCH

--I COMPRESSOR CONTROL RELAY

HORNRELAY

FROM FRONTPOWER V DISTRIBUTION BOX

RED

FRONTPOWER I DISTRIBUTION BOX

FUSE F43 5A- -

FUSE I I F42 T7 .SA -- I

5 CENTER CONSOLE TELEPHONE CONNECTOR

L-1

REAR DEFOGGER RELAY

I I

-I

I I

BODY ELECTRONICS CONTROL MODULE (ZKE IV)

I L-1

! _I

ELECTRONIC IM MOBLIZER CONTROL MODULE (EWSII)

F -, I I

SEAT OCCUPANCY DETECTOR

RIGHTSIDE IMPACT SENSOR

I I

LEFTSIDE IMPACT SENSOR

I I

NORMAL SPEED RELAY

I I

HIGH SPEED RELAY

I ( -I

LEFT MAKEUP MIRROR LIGHT

I I I

I I

_I FRONTDOME/ MAPLIGHT ASSEMBLY

( I

I I

- I

ANTI-THEFT CONTROL MODULE

I 1

LUGGAGE COMPARTMENT TELEPHONE CONNECTOR

RIGHT MAKEUP MIRROR LIGHT

TRANSMITTER MODULE 88138

-_A_______________`15_-__________________51Z15A-________ _ 30Y 32

2 I I

I I

STARTER IMMOBILIZATION SWITCH

I I

INSTRUMENT CLUSTER

SRS CONTROL MODULE

-------------------------------------------------------- - - - FRONTPOWER FROM FUSEF43 G I DISTRIBUTIONBOX (DIAGRAM 2OF3) I FUSE FUSE FUSE I I F45 F48 F46 I _______

I L-1

I I

!_I

BLOWER RELAY

F -, I I

I I

6),

I I

BLOWER RELAY

I I

(DIAGRAM 20F 3) -------------------TO RUSE F45 G (DIAGRAM 2 OF 3) FUSE FB 30A --------------------

1),

! _I

B),

INSTRUMENT CLUSTER

--USE 20 OA -----

I I

! UNLOADER RELAY

ENGINE CONTROL MODULE(ONE)

s),

I I

FROM RED FRONT POWER ~ DISTRIBUTION BOX (DIAGRAM 1 OF 3) 111 ____________,

I I 1

Ilk

I I

BODY ELECTRONICS CONTROL MODULE (ZKEIV)

I I

BRAKE LIGHT SWITCH'

I I

CRUISE CONTROL MODULE

I I

CRUISE CONTROL SWITCH

I I

DIGITAL CLOCK

I I

ON-BOARD COMPUTER

DATALINK CONNECTOR

GL LIGHT

I -I

WIPER/ WASHER MODULE

L-1

WIPER/ WASHER SWITCH

I -I RADIO

I -I

REAR WIPE R/ WASHER CONTROL MODULE

ELECTRICAL WIRING DIAGRAMS

ELE-31

Power Distribution 1997 318ti (3 of 3)

FROM FRONTPOW .R D ISTRIBUTION BOX (DIAGRAM IOF3) TO

RED

FROM FRONTPOWER DISTRIBUTION BOX (DI AGRAM10F3)

RED f~~ E 1/ ~1 11

_ _ _ _ _ _ _ _ _ _ - - __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ __ _ _ _ _ -

FUSEF33 (DIAGRAM 3CF3)

FUSE F30 15A

____

FUSE F36 30A

101

61 ~l

F -,

I - i

I I I _I

FUSE F36 25A 121

I I L-1

I I ! _I

I I L-1

,a1

___________

761

WITH ABC

¢I

F -,

291

201

¢I

I I L-1

SLIP CONTROL MODULE

ADS CONTROL MODULE

FUSE F7 sA

~ II

FRONTPOWER DISTRIBUTION BOX

WITH ABC

FUSE FB 15A

I i

F -,

I I L----l

LIGHT SWITCH

FU FUSE F1 S F9 3020A _____

WITH ADS

WITH ABS

I --- i

I I L-1

I --,

HAZARD BODY WIPERI FLASHER ELECTRONICS WASHER RELAY CONTROL MODULE MODULE (ZKEIV)

.HAS. CONTROL MODULE

101 Flhh. i

FUSE FUSE F37 F38 1-------OA

1 j --

ABS CONTROL MODULE

1 j -_

ADS PUMP MOTOR RELAY

RADIO

1 j -_

HIFI AMPLIFIER

1 j -_

HORN RELAY

LEFT .OR . LOCK SWITCH

1 1 1 j --_

RIGHT DOOR LOCK SWITCH

LEFT DOOR LOCK MOTOR

1 j -_

RIGHT DOOR LOCK MOTOR

1 j -_

TRUNK CENTRAL LOCK LCOKING MOTOR SWITCH

r_________-__--__________________________________--____-_________-IFRONTPOWER II I

FUSE F24 (DIAGRAM FRO 30 F3)

FUSE F23 . . L______-_________________}}}L'''D"__________________ I

GRIBLU I

IT H HS

WITH INKS

I I

F-, I ~

FUSE 1`32 30A

BLK/WHT /

F-, I I

1 1 .!l

1 _I WATER VALVE

71 ..iii

I-

L-1

FRESH INKS AIR CONTROL RECIRULATION SWITCH MOTOR

FROMIGNITION SWITCH (DIAGRAM 20F3)

JETHEATER THERMO891 SWITCH 38

RIGHT SIDE MIRROR

B~ I I

I- v I I

L-1

I I

CIGAR LIGHTER

NT "

BRNI

OBDII CONNECTOR

G203

CENTER CONSOLE TELEPHONE CONNECTOR

I -I

I I

LIGHT SWITCH

T I I

L-1

REAR COMBINATION DEFOGGER SWITCH SWITCH

I I

ELECTRONIC IM ILIZER CONTROL MOB MODULE

GRN 1

DISTWBUTIONBOX

I I I

F-, I I

UNLOADER LIGHT FOG LIGHT RELAY SWITCH SWITCH ILLUMINATION ILLUMINATION

FROM FUSE F34 (DIAGRAM 30F3)

INSTRUMENT REAR CLUSTER DEFOGGER RELAY

I- v I I

FUSE F33 10A

________j

- - - F - - - *----o GRIBLUl

FUSE F31 SA

I I

CHIME MODULE

I I

ON BOARD COMPUTER

DIGITAL CLOCK

I I

INSTRUMENT CLUSTER

I I

_ BODY ELECTRONICS CONTROL MODULE (ZKEIV)

, I

L-1 RIGHT TRUNK LIGHT

I I

! _I

CD CHANGER

I I

I LUGGAGE ( COMPARTMENT TELEPHONE CONNECTOR

! _(

FRONT DOMEIMAP LIGHT ASSEMBLY

- - _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ , FRONT POWER I DISTRIBUTION BOX

MIRROR CONTROL SWITCH

LIGHT SWITCH

HIGH BEAM LIGHT RELAY

REVERSING LIGHT SWITCH

AUTOMATIC TRANSMISSION RANGESWITCH

PROGRAM SWITCH

INSTRUMENT CLUSTER

LIGHT SWITCH

ADS CONTROL MODULE

SLIP CONTROL MODULE

ASC SWITCH

ELE-32

ELECTRICAL WIRING DIAGRAMS

Power Distribution 1998 318ti (1 of 3)

B . JUMP START JUNCTION POINT

RED

FUSE LINK RED

I I UNLOADER RELAY

2 O

I I

ENGINE CONTROL MODULE HOME)

ENGINE CONTROL MODULE RELAY

TRANSMISSION CONTROL MODULE(EGS)

GENERATOR

SECONDARY AIR PUMP RELAY

I I

STARTER

BATTERY

15IX74419 ------------- FRONTPOWER I DISTRIBUTIONBOX

FU BE I

15A 1~sTxLn91B ^ ------------------

RED

TOFSEFB (DIAGRAM 20F3) 30A

I I

TO IGNITION SWITCH (0)M 20F3

TO FUSE F3. (DIAGRAM 2 30F3) T

t-_-_______

1588

71XSnn]5

17~X1D018

7~XLQOifl

1~X1DD15

I AU%ILIARV TO FUSE F20 7IC FUSEFUSEBO F4 SE F USE I X (DIAGRAM IF14 F89E 20F3)0 .SA I _Y'__J 5 ___- 7 -__ -___ -_ 21x7588 BIX1 ts Is x1DDIB . elx1n9~6

TO FUSE F . (DIAGRAM 30F3)

- FRONTPOWER FUSE iDISTRIBUTIONBOX FI

30__I 1DD1B

SUNROOF Bl

I I

I FUEL PUMP

I I

HIGHS PEED RELAY

UNLOADER RELAY

~ I

81 I I

I I

ROOF

COMPRESSOR BODY CONTROL ELECTRONICS RELAY CONTROL MODULE (ZKEIV)

SUNROOF CONTROL ASSEMBLY

____________-__-__

4 2x0 AUXILIARY FUSEBOX

I I

FUSE F47

I I

HIGH BEAM LIGHT RELAY

FRONT I FOG ( LIGHT -~ RELAY

I I

81 ..+++.

LOW ( BEAM ( LIGHT RELAY

-~ I

I I

30-J

19254

3 I

FUSE --------FUSE --_[F3 75 . ! ._ fi7x14n]5.

BODY ELECTRONICS CONTROL MODULE (ZKEIV) 10442 8

ANTI-THEFT CONTROL MODULE

REAR WIPER/ WASHER CONTROL MODULE

WIPER/ WASHER MODULE

20Y

RIGHT HEADLIGHT

FUSE

753_A3__-_______ X7D91Z

LEFT HEADLIGHT

t0YX1901B .

PASSENGER'S SEAT CONTROL SWITCH

20x1491&

DRIVER'S SEAT CONTROL SWITCH

FDGLFGHT

RIGHT FOO LIGHT

INSTRUMENT CLUSTER

RIGHT HEADLIGHT

LEFT HEADLIGHT

ELECTRICAL WIRING DIAGRAMS

ELE-33

Power Distribution a

1998 318ti (2 of 3)

FROM FRONT POWER DISTRIBUTION BOX (DIAGRAM I OF 3)

----------------------------------------------------I IGNITION SWITCH

I I OFF

START

-----------------

-- START

OFF

A__ R_N_______________________C__" RU-

START

OFF

---- OFF ACC

I I

START -U___

2 3 "'fY

NOTUSED

I-]

I I

TO FUSE F14 (DIAGRAM 3 OF 3)

FUSE 28 5A

I I

ENGINE CONTROL MODULE (DME)

FROM FRONTPOWER DISTRIBUTION BOX j~(DI=G=AM110F3)) -

XISLOIL

I I

BODY ELECTRONICS CONTROL MODULE (ZKEIV)

5681

I I

UNL0ADER RELAY

INSTRUMENT CLUSTER

F-, I I

BLOWER RELAY

ELECTRONIC IM MOBLIZER CONTROL MODULE (EWSII)

X14pTg

FUSE F20 30A 2C1X1DD18

HORN RELAY

T O FUSEF45~C~~~GIIII--~~~I (OIAG RAM20F3) V I yFUSE FUSE ) F42 [ F43 T JJJccc___,,,______________ 575 v - - 24 X19073

RED 19

121

F-, I I

FROM FRONTPOWER DISTRIBUTION BOX (OIAGRAM10F3)

RED

FUSE F15

167Xj991Z

I I

USE F6 3° 001

=X10

I- -

I- I I

I - , I

SEAT OCCUPANCY DETECTOR

DRIVER'S SEAT BELT SWITCH

RIGHT IMPACT SENSOR

I BLOWER RELAY

I I

I _I AUTOMATIC TRANSMISSION RANGE SWITCH

I _I COMPRESSOR CONTROL RELAY

' _I NORMAL SPEED RELAY

REAR DEFOGGER RELAY

BODY ELECTRONICS CONTROL MODULE (ZKE IV)

I I

_I HIGH SPEED RELAY

I I

I _I DRIVER'S MAKEUP MIRROR LIGHT

FUSE 145

FUSE 146

16 I i I

I _I TRANSMITTER MODULE 10442 9

I I

F -, I

_I STARTER IMMOBILIZATION SWITCH

I I

26I

I I I

L -I INSTRUMENT CLUSTER

I I

I - I ANTITHEFT CONTROL MODULE

L -I BRAKE LIGHT SWITCH

I I

L_I CRUISE CONTROL MODULE

I I

1 -7 , I

L-1 CRUISE CONTROL SWITCH

L -I DIGITAL CLOCK

I I

L -I BOARD COMPUTER

DATALINK CONNECTOR

I - -i I I

I I

LUGGAGE COMPARTMENT TELEPHONE CONNECTOR

- F, RO NT I OISTRIBUTION80X I

15A-_________

cLOVEeox LIGHT

S1 I

F -1 I I ,,- - I

I 1

WIPER/ WASHER MODULE

WIPER/ WASHER SWITCH

PASSENGER'S LEFT SUPPLEMENTAL SEAT IMPACT RESTRAINT BELT SENSOR SYSTEM SWITCH CONTROL MODULE

I _I PASSENGER'S MAKEUP MIRROR LIGHT

FUSE F41

>I 5I 10T 1T > I I

I - -i I I

I I

I _I FRONTDOME/ MAP LIGHT ASSEMBLY

7 .-A-__--_____15A --------------------

_________-_____________________

G FROMFUSEF43 (DIAGRAM2OF 3) V

FRONTPOWER

I DISTRIBUTION BOX I I -J

I I

I I RADIO

I I

REARWIPER/ WASHER CONTROL MODULE

ELE-34

ELECTRICAL WIRING DIAGRAMS

Power Distribution 1998 318ti (3 of 3)

FROM FROM RED RED E FRO-POWER FRONT POWER D DISTRIBUTION BOX DISTRIBUTION BOX X1003D (DIAGRAM IoF3) (DIAGRAM IOF3) X.LD024 1 ------------------------------------------------ ----------I

I I

TO FUSEF33 (DIAGRAM 30F3)

I _I

CRASH CONTROL MODULE

FUSE 131 15A

FUSE 135 25A

1--i

! _I

HAZARD BODY WIPER/ FLASHER ELECTRONICS WASHER RELAY CONTROL MODULE MODULE (ZKEIV)

WIAUTO CLIMATE CONTROL

! _I

LIGHT SWITCH

SLIP CONTROL MODULE

WATER VALVE

I --[

FROM IGNITION SWITCH (DIAGRAM 20F3)

RADIO

! _I

1 _!

! _I

HIFI SUBWOOFER AMPLIFIER

PASSENGER'S DOOR LOCK SWITCH

1 _!

TRUNK LOCK MOTOR

1 _l

PASSENGER'S CENTRAL DOOR LOCKING LOCK SWITCH MOTOR

REAR DEFOGGER SWITCH

COMBINATION SWITCH

1 I

- I

ELECTRONIC IM ILIZER CONTROL MOB MODULE

GRN 1 XIR02fi _

CHIME MODULE

1 I I

1 I

1 I I

- I

BOARD COMPUTER

1 I

_I INSTRUMENT CLUSTER

DIGITAL CLOCK

1 I

_I _I BODY RIGHT ELECTRONICS TRUNK CONTROL LIGHT MODULE (E ASSEMBLY

1 I

_I CD CHANGER

2j5 4 1 1~ 4 I ~h I

1_I

! _I

PASSENGER'S MIRROR SIDE CONTROL MIRROR SWITCH 104430

I I

! _I

JE7HEATER THERMOSWITCH

I I

I 1

!_I

LIGHT SWITCH

! _I

DRIVER'S DOOR LOCK SWITCH

1 Loccace / COMPARTMENT TELEPHONE

_I CONNECTOR FRONT COME/MAP LIGHT ASSEMBLY

_______________________-____________-I FROHIPOWER I DISTRIBUTIONSOX JIUSE

10AE________

F2 SA 5A

5A7

. E

WITH ABS

II I

SASE

GRN/ BLU/YEL

DRIVER'S DOOR LOCK MOTOR

FOG UNLOADER LIGHT LIGHT RELAY SWITCH SWITCH ILLUMINATION ILLUMINATION

ASE-_____________

I I

1 _l

F B

I -,-I

L _I

FRESH IHKS Cl AIR CONTROL RE RULATION SWITCH MOTOR

ABS PUMP MOTOR RELAY

I I I I F I I F I I I I I I F I -I _I L-1 L-1 L -I L-1

W/OAUTO

CLIMATE al CONTROL

F l F 1 I I

I I

I__I L -j

ABS CONTROL MODULE/ HYDRAULIC UNIT

INSTRUMENT REAR CLUSTER DEFOGGER RELAY

I I

! ___I

( BJ~. I I

2,~ I I

! _I

HIGH BEAM LIGHT RELAY

I I

113), I I

! _I

DATA TA LINK CONNECTOR

REVERSING LIGHT SWITCH

1 I

I _I

AUTOMATIC TRANSMISSION RANGE SWITCH

I .+ . I I

! _I

G RN/ BLU/YEL 1 I

PROGRAM SWITCH

23 ~ .~. I I

1 I

L-1

INSTRUMENT CLUSTER

~ 2IS 1 I

WITH ASC

GRN/I BLU/YEL/

4 1 I

! _I LIGHT SWITCH

1 I

GRN/ BLU/YEL

4 1 I

! _I

ABS CONTROL MODULE/ HYDRAULIC UNIT

1 I

!_I

5 1 I

SLIP CONTROL MODULE

1 1

L-1 ABC SWITCH

ELECTRICAL WIRING DIAGRAMS

ELE-35

Ground Distribution 1992-93 (1 of 5)

I I

I I I

RIGHT HIGH (BEAM LIGHT

(CANADA)

I I I

II I I_ I ,7

HEADLIGHT/ FOG LIGHT WASHER

I I

WASHER FLUID LEVEL SWITCH (GSA)

_ _ _ _ _ _ _ _ _ _ _

-. (

LEFT ) PARK

- 1 I

(

I I

(

ENGINE COOLANT ( LEVEL SWITCH _ I

I I

I _ _I

(

LEFT LOW ( BEAM LIGHT (

I I

LEFT HIGH (BEAM ( LIGHT

I I

LEFT ( HORN I

LEFT ) FOG LIGHT

I I

L-1

I I I

( v

CONTROL 'CONTROL (ACTUATOR

I _ -I

L-1

RIGHT ) FOG LIGHT

FIGHT ( HORN I

I I

1-1ONLY

I __--_JI

I I

I I I I

PRESSURE SWITCH

(TEMPERATURE I SWITCH

I I I

WASHER PUMP (CANADA)

RIGHT ) FRONT TURN LIGHT

(

I I I ( I I

RIGHT ) FRONT PARK LIGHT

LEFT ) FRONT TURN LIGHT

DIMMER

I I

(

!7T , ,

I I L_

(

BIGHT LOW BEAM LIGHT

AUXILIARY ( FAN ( MOTOR

( I

"°"'

I I

II II I _I

RIGHT ) FRONT AUXILIARY TURN LIGHT

(

II II _I

LIGHT SWITCH

I I

INSTRUMENT CLUSTER

BRN LEFT PARK LIGHT RELAY

IGNITION II SWITCH I

STARTEP RELAY

WIPER/ I WASHER I --II SWITCH I I

II 4L Gill 6111

_ (

)

CASSETTE BOX

I I

LIGHT

HORN I SWITCH I (COMBINATION SWITCH)

~-I ~f- 1993 ONLY 1992 4- ONLY

BRN

SPIN

FROMLEFTWASHER JETHEATER (DIAGRAM20F3)

1 G202

I I

(

I I

LEFT ) PARK .LIGHT

I I I

I I I I I I

(

LEFT ) FRONT TURN LIGHT

1993 ONLY

84831

ON-BOARD ( COMPUTER I I I_ - I I

UNLOADER ( RELAY

I I

-I 9

I I I I

CIA ME ( MODULE I

I I I

1993 ONLY

I I I

LEFT ( SEAT ( HEATER SWITCH _(

BLOWER I RELAY I _)

- 1993 ONLY

I I I

DIMMER ( SWITCH I

I I ~ 4 BRAKE ( LIGHT ( SWITCH _I

(

I I I

RIGHT ( SEAT ( HEATER SWITCH I

RIGHT ) FRONT AUXILIARY TURN LIGHT

"- 1992 ONLY

ELECTRICAL WIRING DIAGRAMS

ELE-36

Ground Distribution 1992-93 (2 of 5)

(

LEFT WASHER (JET HEATER ( (CANA DA)

( I (CANADA)

J, I

( I

s'(

ASS RELAY

(

BRAKE FLUID (LEVEL ( SWITCH

I I

( I

WIPER MOTOR

( I

WIPER RELAY ((CANADA)

I I

B'(

( I

HAZARD FLASHER RELAY

( I

COMFORT RELAY

(

RIGHT WINDOW RETRACTION

(

I I

BRN

70 G202 (DIAGRAM 1 OF 5)

( I

I I

CENTRAL ( LOCKING ( MODULE

RIGHT WASHER (JET HEATE

( (

BLOWER RELAY

( (

I I

(

( INERTIA SWITCH I

WIPER( WASHER MODULE (USA)

LEFT ) FRONT AUXILIARY TURN LIGHT

(

_ I

I I

LEFT MAKEUP

SWITCH

(

MODULE

-I

( RIGHT SIDE (MIRROR

RIGHT POWER

( WINDOW

9 I

( MIRROR

( RIGHT MAKEUP (MIRROR SWITCH _I

-I

(

AISSEMBLY

-1993

LOW BEAM LIGHT ( RELAY (

1--,FP ONT DOME/ ( MAP I

SUNROOF CONTROL ASSEMBLY

I I I

(

if -

2 LEFT SEAT (BELT SWITCH

-2 ONLY

3 II

HIGH BEAM LIGHT RELAY

i RIGHT DOOR (JAMB SWITCH -I

- I HANDLE CONTRACT SWITCH (EARLY PRODUCTION)

ONLY

I I

LEFT I H EATBACK ( EATER -I

I I I

RIGHT ( SEAT ( BELT S WITCH

v -I

I SEATT ( CONTROL SWITCH

I I I

I I

-( v

RIGHT I SATBACK HEATER

MIRROR ( CONTROL ( SWITCH

I I I

LEFT ( POWER ( WINDOW MODULE

I I I

v-I

I I I

-I

-1

I SEDE ( MIRROR

I I I

-I

-(-I

I I I

_ v

( DOOR ( JAMB (SWITCH

LEFT ( WINDOW ( RETRACTION DOOR ~I HANDLE CONTRACT SWITCH (EARLY PRODUCTION)

x1993

ONLY

J -L

I I I

(LEFT POWER ( WINDOW SWITCH -I

I I I

LEFT ( POWER ( WINDOW - I MODULE

I I I

RIGHT ( POWER ( WINDOW SWITCH_ -I

I I I

LE T ( REAR I DOOR POWER -I WINDOW SWITCH (CONSOLE)

RIGHT ( REAR I DOOR POWER I -I WINDOW 1 SWITCH (CONSOLE) Y I I

-1992 BR

ONLY

64852

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-37

Ground Distribution 1992-93 (3 of 5)

IGNITION COIL SHIELD

IGNITION COILS SHIELD

I I

ENGINE I CONTROL ( MODULE (DME)

I I I

U IGNITION COIL2 SHIELD

F_==a IGNITION COIL4 I _ SHIELD

(

IGNITION I COIL2 I

IGNITION I COIL4

I I

-I

( I _I

IGNITION COIL?

_ _

IGNITION COILS

l CAMSHAFT

POSITION SENSOR _j SHIELD Q

CAMSHAFT POSITION SENSOR SHIELD

CAMSHAFT POSITI S

: Q

== CAMSHAFT POSITION (SENSOR _ _ SHIELD

ENGINE (CONTROL ( MODULE (DME)

I I 28

ONLY

BRNIO

I I I

NCA

HEATED OXYGEN I SENSOR I

I I I

HEATED (OXYGEN SENSOR SHIELD

----

I TRANSMISSION CONTROL I MODULE (EGS)

1993 ONLY

DATA LINK CONNECTOR

I I

G123 (318SERIES)

I I I

HALL EFFECT (CAMSHAFT SENSOR

-I

1993 ONLY

'~ DATA LINK CONNECTOR

HEATED I OXYG

F=_ :

( SENSOR

HEATED OXYGEN SENSOR SHIELD

I I

HOT FILM (AIR MASS METER

I I

CRANKSHAFT ( POSITION/ RPM ~~ SENSOR SHIELD

361

ENGINE ( CONTROL I MODULE

I I

NC NCA _ NCA

TRANSMISSION I CONTROL (MODULE (EGS)

-I

BRNIORG

(325 SERIES) 64853

PUMP ( MOTOR RELAY

r '

CAMSHAFT POSITION SENSOR ,~ SHIELD

199 : ONLY

I I

=Y=1 mI CAMSHAFT POSITION SENSOR _ -~ SHIELD

I ( I ---I

HYDRAULIC ( UNIT

CRANKSHAFT I POSITION/ __ RPM _j SENSOR SHIELD __

I __~_

I ( I -I

PUMP ( MOTOR RELAY

( _I

IGNITION COIL SHIELD

ELECTRICAL WIRING DIAGRAMS

ELE-38

Ground Distribution 1992-93 (4 of 5)

MULTI( FUNCTION ( CLOCK

I I

Ily

SWITCH

((

_ I_

SRA)LE CANADA)

I I

((

Ay I (

I I

GLOVE

I ( LIGHT BOX

HEADLIGHT/

I FOGLIGHT ( CLEANING

HAZARD SWITCH HORN

ANTITHEFT HORN

(( I

(I _I

CHARGING SOCKET

RADIO MICROSWITCH

I I

(( I

I I

( ( I

II I( I_ I

ENGINE HOOD SWITCH

ON-BOARD COMPUTER

13Y

TWIN RELAY MODULE (CANADA)

I I

( ( I

I I

TRANSMISSION POSITION INDICATOR LIGHT

((

I I

INTENSIVE WASH PUMP

(

IHKR ( CONTROL ( MODULE

I I

L-1

INTEGRATED CLIMATE ( REGULATION

BLOWER ( MOTOR I

I I

! _____JMODULEL

FIGHT

-T

L-1

2 '

PROGRAM ( SWITCH I (WIEGS)

I I

PRONT

FRONT

I LICENSE LIGHT 4,F RELAY (CANADA)

I ,

LIGHTER LIGHT

REAR _ v

I LIGHTER I

FRONT

LIGHTRAY

LIGHT

CASSETTE

BIGHT

1992 ONLY

BRN

G2D3

IGNITION I COILl I

I I I

IGNITION ICOIL2 I

I I I

_I 2

IGNITION I COIL 3 I

I I I

IGNITION I COIL4 1

I I

IGNITION (COILS I

I I I

IGNITION (COILS I

I I

_I 2

ENGINE ( CONTROL ( MODULE __y(OME,

I I I ,m

ENGINE CONTROL MODULE SHIELD 1993 ONLY

CRUISE I CONTROL ( MODULE _I

I I I 17/

CRASH I CONTROL ( MODULE - I (USA)

I I I B/

INSTRUMENT I CLUSTER I - I

I I I 24/

WIPER/ I WASHER

I I

( MODULE - I (USA) 16/

G2D3

64869

WIPER/ I WASHER ( MODULE - I (CANADA)

I I 2S

I I

I ON-BOARD COMPUTER (TEMPERATURE - I SENSOR

ELECTRICAL WIRING DIAGRAMS

ELE-39

Ground Distribution 1992-93 (5 of 5)

I I I

LEFT REAR TURN LIGHT

(

I I I I I

I I

(

LEFT

) TAIL

LIGHT

LEFT

) BACK- UP LIGHT

(

rFIGHT TRUNK RIGHT ~' RIGHT LIGHT REAR ( ) BEAR_ (ASSEMBLY TURN FOG LIGHT LIGHT

I i

(ASSEMBLY

I I I I I I

( ^ ) BRAKE LIGHT

(

)

I I

LEFT ) TAIL LIGHT

______________J

G312

I _ II ( ) i

,LEFT (TRUNK G

LEFT REAR FOG LIGHT

LIGHT

I I

LIGHT

I I I I

I I

LEFT

- RIGHT ( ) TAIL

I I

LICENSE

(

FIGHT

( ^ ) BACK UP LIGHT

(

RIGHT ) TAIL LIGHT

(

) LICENSE LIGHT

I I

I SEAT LOAD ( ASSEMBLY

( I Y

( SEAT HEATER

I CHECK CONTROL ( MODULE

I I

-I

( CHANGER I

I SEATBACK I l HEATER IY I

I LEFT REAR ( DOOR

(

I I

( AMPLIFIER

i I

HIFI

WIHIFI . TENSPEAKER SYSTEM

64882

( FUEL PUMP

I I

I---

I I

= Y ~~Y

______________J

CONTACT

ONLY

( B

) BRAKE LIGHT

-7993

I I

(

DOOR (JAMB SWITCH (4DOORI

LEFT (SEAT (CONTROL SWITCH

REAR (BRAKE PAD SENSOR

LEFT ( FRONT

I RIGHT

I I I

I I i

I RADIO I

WISTEREO BSPEAKER SYSTEM

( LEVEL

I ( STOP I_I _ ( LIGHT V

I II

( DOOR ( JAMB -(SWITCH v

( ANTITHEFT

( CONTROL

MODULE

I FILTERESSION I v I (2DOOR) I__I I

I I I

I RIGHT ( REAR DOOR

_I CONTACT

I TELEPHONE I TRANSCEIVER

ELECTRICAL WIRING DIAGRAMS

ELE-40

Ground Distribution

1994-95 Except 318ti (1 of 5) I I

HEADLIGHT/ FOG LIGHT I WASHER (PUMP

I I

RIGHT HIGH I BEAM (LIGHT

I 1

_ _

I I

, L-

(TEMPERATURE SWITCH

WASHER (PUMP I(CANADA)

I I

PRESSURE SWITCH

RIGHT )FOG LIGHT

LEFT I REAR ( WINDOW I-r- SWITCH (6 DOOR) I

¢1

PCHILD , ROTECTION I ]CONTROL I (CONSOLE) -- ( (L DOOR) 3

, FEAR' (DOOR I I (CONSOLE) -- ( POWER SWWINDOW S WSWITCH ITCH (4 DOOR)

REAAT (POWER WINDOW -- SWITCH (CONVERTIBLE) S

ANTIIITHEFT IIHORN (1995)

I I

LEFT I REAR I ( DOOR I ((CONSOLE) -- POWER WINDOW SWITCH (C DOOR)

I (-

-. m

I I I

LEFT I REAR ( POWER I (WINDOW I -- SWITCH (CONVERTIBLE(

RIGHT FRONT TURN LIGHT

I I

-1 RIGHT LOW (BEAM LIGHT (

I I I

WASHER (FLUID (LEVEL SWITCH

RIGHT PARK LIGHT

-1_ G302

-I

I I

, I

RIGHT HORN

I I

LEFT

'DRIVERS

(

(WINDOW ( SWITCH

¢~

LIGHT

LEFT II HORN II

LEFT LOW (BEAM (LIGHT -

I I

LEFT FRONT (- TURN LIGHT ---

(LEVEL SWITCH

) PARK LIGHT

ENGINE I COOLANT

I I

LEFT HIGH I LIGHT

- -

I I

( I (

AUXILIARY FAN ( MOTOR

(

¢~

(PASSENGERS ( POWER WINDOW (SWITCH

]

¢~

(CENTRAL (POWER WINDOW ( SWITCH (CONVERTIBLE)

CRUISE I CONTROL (ACTUATOR

-I

I_ 1

G302 /A BF.

LEFT , WASHER (JET _ (HEATER

I I

FRONT ( FOG [LIGHT -(RELAY

I I I

WIPER ( MOTOR I

I I I _

I I i

THROTTLE (FLAP (HEATER SWITCH

OW (LBEAM (LIGHT I I_ - IRELAY I

RIGHT WASHER (JET (HEATER

I I

BRAKE ( FLUID (LEVEL SWITCH _(

I I I

BRN

ASS RELAY

COMPRESSOR ]CONTROL IRELAY (SWITCH

I I I

WIPER RELAY ((CANADA)

I v

(

(LOW 11)

LEFT ) FRONT AUXILIARY TURN LIGHT

s HIGH (BEAM ,LIGHT IRELAV

I I

WIPER/ ( WASHER MODULE

I I I _

I I I

BLOWER I RELAY I

I I

HAZARD (FLASHER IRELAY I

CHIME MODULE

I I I

DRIVERS SEAT. BEAT , HEATER SWITCH -I

I , I

-I 1

6 UNLOADER ,RELAY I

I I

I "T

, I

DIMMER

-I 6

BRAKE LIGHT ( SWITCH

I I I

I ^T

PASSENGERS ,SEAT,SEAT ( HEATER SWITCH

I I I °T

BRN

8431 8

I I I

(

LIGHT ,SWITCH I

I I

RIGHT ) FRONT AUXILIARY TURN LIGHT

I_ -I 7

I I 3

LEFT ( PARK (LIGHT RELAY -I

I I I_I

I ]

IGNITION SWITCH

INSTRUMENT , CLUSTER I

I I

STARTER ,RELAY I

I I

WIPER/ WASHER SWITCH I

BRN

I I

HORN , SWITCH I

ELECTRICAL

Ground

1994-95

DRIVERS , WINDOW

I I

( DRIVERS DOOR IJAMB SWITCH

I I

(MOTOR

DOOR ( LOCK IHEATER

I I I

Y DRIVERS ,SIDE ( MIRROR

I I I I

MIRROR ( CONTROL ( SWITCH

I I

I--I

DRIVERS ( DOOR I HPNDLE SWITCH

318ti

IF'' r I I I

9 I I

Except

(MOTOR RELAY _(

I I

_-I

I I

S-I(ZKEIIVE

RELAY , MODULE I

I -

DRIVERS ( SEAT (BELT SWITCH

SUNROOF (CONTROL (ASSEMBLY

I I

- I

I I

a m

-I

I I I

I HOT FILM I AIT MP SS I METER

PASSENGERS , MAKEUP

(MACRO SWITCH

I I

FRONT , DOMELIGHT1 (MAP I I READ - - - - I ASSEMBLY 4

(MIRROR SWITCH

DRIVERS (MAKEUP (MIRROR SWITCH

I I

PASSENGERS ( BIOS (MIRROR I

_ PASSENGERS I , DOOR I (JAMB I SWITCH - _I

--CONVERTIBLE

CONVERTIBLE TOP

WINDOW I--iMOD I

MOTOR

BR I I I

-,P ASSENGERS SEAT (BELT SWITCH -I

I I

IDOORENGERS

I I

(JAMB - (SWITCH

PASSENGERS , SEATBACK IHEATER

I I I

SESSSENGERS

(CONTROL SWITCH

PASSENGERS , SEAT HEATER

I I

- I

HANGER

.I I I I

HEATED (OXYGEN (SENSOR

ENGINE (CONTROL (MODULE - ((ONE)

281 1. DATA LINK CONNECTOR 1

ENGINE ,CONTROL ( MODULE j(ONE)

II I 55

I___~IGNITION COILS SHIELD

I I I

CYL2 I IGNITION ( COIL

2 I I

I GRITION I COIL

CYL4 I IGNITION ( COIL

3 IIGNITION I COIL

I I I

( el

_-1

HEATED FOXYGEN( SENSOR NCA SHELLD -~-~~ TRANSMISSION (CONTROL I MODULE

I I BRN RESISTOR

19 ¢1

38 K

BRN BRN BRN BRNIORO

t_ G103 (3181) 84319

- ~ CAMSHAFT I POSITION II, SENSOR N___~SHIELD

~__-CAMSHAFT I POSITION SENSOR _ _ SHIELD

I 2

1sY

BRN

ENGINE I CONTROL ( MODULE (DME)

_------

IGNITION I COILS SHIELD

TRUNK ( LID v

OATP LINK CONNECTOR

I-

CONVERTIBLE ( TOP (STORAGE LID LOCK - I MOTOR

I I

FASC+T

G201

INERTIA , SWITCH I I

---

TRANSMISSION ( CONTROL (MODULE -(( EGS)

```~~~'''_I 2¢0'

G202

BODY ( ELECTRONICS (CONTROL

I I

f ASCtT

ELE-41

SLIP (CONTROL (MODULE - _j(PBSIASC)

ABS , HVDRPULIC ( UNIT

DIAGRAMS

Distribution

ABS ( PUMP

I I I

WIRING

F___~ CRANKSHAFT I POSITIONIRPM L _ SENSOR }___SHIELD

CRANKSHAFT IOSITIONIRPM __ SENSOR __ SHIELD

ELECTRICAL WIRING DIAGRAMS

ELE-42

Ground Distribution

1994-95 Except 318ti (3 of 5) IGNITION COILS ( SHIELD

HEATED IOXVGEN (SENSOR

CONTROL (MODULE _-J(OME)

I I

HEATED OXYGEN I SENBOR -~ SHIELD

¢~

ENGINE ( CONTROL MODULE (DME)

(

I HEATED (OXYGEN SENSOR, -- SHIELD

HEATED (OXYGEN ISENSOR2

CAMSHAFT POSITION _ SENSOR ---~ SHIELD

CRANKSHAFT POSITION/RPM _ SENSOR -~ SHIELD

I AIR

I I

I MASS

M ETER

DATA LINK CONNECTOR

0-0

ENGINE (CONTROL (MODULE _ (DME)

I I

--- I VARIABLE CAMSHAFT (CONTROL MODULE ---- (VANOS)

I BRN/ORG BRN

IGNITION

I ENGINE CONTROL I MODULE

I I

(DME)

By 347 287

SENSOR 1 SHIELD

SENSOR2 I SHIELD

(VARIABLE CAMSHAFT (CONTROL - ISENSORI

I I I

(VARIABLE CAMSHAFT (CONTROL - I3ENSOR2

I I I

I POSITIONIRPM SENSOR

=__ k -

I-

F---D,SENSOR2 SHIELD S I

CRANKSHAFT

I COILS SHIELD

SENSOR 1 SHIELD

G103 (M3CANADA)

557

(CHANGEOVER I VALVE

I I

FUEL PUMPf START I IDENTIFICATION I RELAY

I I I

I HOT FILM

CRANKSHAFT POSITION/RPM SENSOR ---~ SHIELD

I AIR PUMP I I I vI

CAMSHAFT POSITN_ _ SENSOR -~ SHIELD_

I _ <

SHIELD

I I

CRANKSHAFT POSITION/RPM SENSOR _~ SHIELD

HEATED ( OXYGEN ; SENSOR

I I

T F NCA~ _ -

BT oI

HOT TRANSMISSION I ( FILM (CONTRL_ (AIR (MODULE I (EGS)I MASS I METER

_ 1Y

_~ HEATED (OXYGEN _~ SENSOR SHIELD

I I I

HALL ( EFFECT (CAMSHAFT SENSOR ._ I

TA 197 LDA IN K oI CONNECTOR

(SHIELD

SRN

BRNIORG

G123 (3251)

I CYL1 IGNITION ; COIL

I I

(

ICYL3 IGNITION ( COIL

I I

2 CYL2 ( IGNITION ( COIL I 2Y

I I

_I 2

I I I

CYL5 IGNITION ( COIL

I I

_I 2

CYL4 ( IGNITION ( COIL I

I I I

I I 17

(INSTRUMENT CLUSTER I

I I

(CRUISE CONTROL ( MODULE _I

I I

I CRASH CONTROL (MODULE -I

I WIPER/ WASHER ( MODULE

I I I

_ I ( USA) I)

RESISTOR BRN/I ORG 1 GROUND

G119 (3201 . 3251 . M3 CANADA) BC321

( WIPER/ WASHER ( MODULE (CANADA)

I I

CYLS ( IGNITION ( COIL

I I I 2Y

(ENGINE IC ONTROL MODULE - I (DME)

o O

BODY ELECTRONICS ( CONTROL MODULE

I I

B ON -BOARD I COMPUTER (TEMP SENSOR I-,- I I I

ELECTRICAL WIRING DIAGRAMS

ELE-43

Ground Distribution

1994-95 Except 318ti (4 of 5)

r----------_-__--,LEFT I I I I

LEFT ( ) REAR TURN LIGHT

LEFT ( ) REAR FOG LIGHT

I I LEFT LEFT I ( ) TAIL ( ) TAIL LIGHT LIGHT I _

LEFT > BACK-UP LIGHT

(

r---__-------~_--,FIGHT I I I I

I IGHTK I gSSEMBLV I I

(

'TRUNK I I AS SEMBLY I I

RIGHT )REAR FOG LIGHT

RIGHT ( REAR ( BRAKE ( PAD SENSOR

I I I

(

L IT SEAT ( CONTROL -( SWITCH

I I

) TAIL LIGHT

I I i

RIGHT ( ) TAIL -~ LIGHT

RIGHT ) BACK-UP LIGHT

LEFT ) BRAKE LIGHT

L_1--------------

RIGHT ) REAR TURN LIGHT

( LEFT

I _RIGHT , FUEL

DRM9T I SWITCH

( PUMP

LEFT SEAT (LUMBAR SUPPO MO70RRVALVE (I9SB)

(4 DOOR)

RIGHT ( > BRAKE , , LIGHT

L-1 -------------- i

TELEPHONE I TRANSCEIVER

---

._I 3T , I

( (

) LICENSE LIGHT

(

RIGHT ) LICENSE LIGHT

I I

(

CONVERTIBLE I TOPSTORAGE I LID MICRO I SWITCH

I I

_ _RIGHT LEFT SEAT REAR ANTERIOR ( ( HEATER _ I LIGHT I _Y Y

LEFT REAR ( INTERIOR I LIGHT

(

I I

(

LEFT I SEATBAIK

I I

Y HEATER - I

(

HIGH LEVEL ( STOP LIGHT _I v .

I I

_LEFT

(

SUPPRESSION FILTER I (2 DOOR)

I-I v

1 G312

MULTI( FUNCTION I CLOCK

I I

I 17T

HEADLIGHT/ I FOGLIGHT I CLEANING MODU (SRA) LE (CANADA,

GLOVE ( BOX ( LIGHT SWITCH _ (

I I I

I_I

HAZARD ( SWITCH ( HORN

INTEGRATED IHKR I CONTROL CLIMATE r( MODULE ( REGULATION I i -----JMODULEL 16

I I

LIGHT

(TELEPHONE EJECTBOX ( (LATE -( PRODUCTION)

G203

84322

ON-BOARD ( COMPUTER I

IaY

I I I

-(LIGHT_

TRANSMISSION ( POSITION ( INDICATOR

I I I

INTENSIVE ( WASH ( PUMP I

ABC I SWITCH I

:PROGRAM SWI TCH (W/EGS)

I I

4 I I I 4

BRN

BLOWER (MOTOR i

_I _I

TWIN ( RELAY ( MODULE (CANADA) L-1

I I

21'

CHARGING ( SOCKET I -I

ENGINE I H000 ( SWITCH

I I I

RADIO ( MICRO( SWITCH

I I

ANTII ( THEFT ( HORN I I _I _

I I

RIGHT ( PARK( ( LICENSE I LIGHT RELAY (CANADA)

`7'

FRONT ASHTRAY LIGHT

FRONT ( CIGAR ( LIGHTER - I

I I 1

4 (

REAR ) ASHTRAY

FRONT ( ^ ) CIGAR LIGHTER LIGHT

CASSETTE BOX LIGHT

ELECTRICAL WIRING DIAGRAMS

ELE-44

Ground Distribution

1994-95 Except 318ti (5 of 5) I ( I -.

I ( -.

PASSENGERS DOOR IAAMB - SWITCH

I I

I ( I -...

PASSENGERS SEAT (BELT -) SWITCH

I I v

PASSENGERS SEAT (CONTROL - SWITCH

I I

RIGHT ( REAR WINDOW - SWITCH

I I

I ( v_I

I ( I v

I I I v

PASSENGERS BEAT (HEATER

I I

PASSENGERS SEATBACK (HEATER

( I

RIGHT REAR (INTERIOR - LIGHT

( _I

I I

CD CHANGER

( I

SUPPRESSION FILTER

I Y

-AG(4 DOOR)

REAR WIN ( BLOWER -(MICR SWITCH 0

REAR WI NDOW ( BLOWER

I I

I _I v

CONVERTIBLE TO ( CONTROL -( MODULE

v I

LEFT REAR I INTERIOR -( LIGHT

I I

RIGHT FEAR I INTERIOR LIGHT _( Y

RIGHT ( DEFOGGER(

I I

DRIVERS I

( MOTOR - LIGHT

I M RROfl

v-I I

DOOR

1 DRIVERS

Iv_I

1 MIRROR

( HEATER

I SWITCH

I _I I

( P ~- I CON TR NECTOR 1

BRN BRN

HARD TOP ICONNECTORI

1 G302 (1995)

-1G312 (CONVERTIBLE)

I I

( DRIVERS SEAT I HEATER SWITCH

I I

PASSENGERS SEAT I HEATER - SWITCH

I I

ROLLOVER I SENSOR I

I-__ I I

CONVERTIBLE -1 TOP , ACTUATING ---( SWITCH

I-

CONVERTIBLE I 70P ( CONTROL MODULE

I I

I I I

CONVERTIBLE I TOP-END ( POSITION

(

SWITCH

I-__

CONVERTIBLE TOP ( POSITION MICRO

I I

ti,

y-( SWITCH

BRN/ ORG

G203

I I

SEAT LOAD ASSEMBLY

I I

CHECK CONTROL ( MODULE -I

I I I

(

LEFT REAR ( DOOR -( CONTACT

I I

ANTITHEFT ( CONTROL ( MODULE

RIGHT REAR ( DOOR -( CONTACT

HIFI AMPLIFIER

I I

RADIO

G203

G202

64323

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL

WIRING

DIAGRAMS

ELE-45

Ground Distribution

1996-97 Except 318ti (1 of 5) _

I I LIJ

I I I

__ I I

HEADLIGHT/ FOG LIGHT WASHER PUMP

RIGHT HIGH BEAM ( LIGHT

LIGHT

II I

(-)

L- -- '

INTERMEDIATE IPRESSUREI (SWITCH -- (1997) 3 '

I I II - I

WASHER FLUID ILEVEL - SWITCH

I I

WASHER (PUMP ( (1996) - (CANADA)

RIGHT_ FRONT TURN LIGHT

I I

I BEAM

_(LIGHT

TEMPERATURE SWITCH

RIGHT (LOW

I I

II I I II

---I

I II

I I I

RIGHT

) PARK

I I

( ) T

I ( II '~ I

fOGH7 LIGHT

PRESSURE ( SWITCH ( (1996)

- ANTII (THEFT ( MORN

I ' i I 1T

AUXILIARY

LEFT HIGH IBEAM LIGHT

(FANMOTOR

ENGINE ( COOLANT ILEVEL (SWITCH

I I I

(-)

I I I I II

LEFT FRONT

RIGHT ,HORN

LIGHT 1------1 1Y '~

CRUISE (CONTROL (ACTUATOR I

I I I_

I I

PARK LIGHT

LEFT MORN

(

LEFT

-T

LGHT

LEFT. ( LOW ISEA

I I

(LIGHT

T G100 1

I I

LEFT ( POP-OUT (WINDOW SWITCH I

RIGHT ( POP-OUT (WINDOW SWITCH

I I

LEFT ( REAR (DOOR (CONSOLE) v- I POWER WINDOW SWITCH (6pDOE)

RIVERS ( POWER WINDOW -(SWITCH

I I

(CENTRAL POWER I IWINDOW I-_( SWITCH (CONVERTIBLE)

T/ ¢~

I Q

CHILD -1 PASSENGERS ( PROTECTION I CONTROL'WINDOW -I S, (CONSOLE) I To. _ (

(DOOR ((CONSOLE) POWER WINDOW SWITCH (4 DOOR)

AIRBAG ( SYSTEM (CONTROL MODULE

I I

rtl

RIGHT ( REAR

I I

LEFT (REAR (WINDOW SWITCH -I(<DOOR)

( CONVERTIBLE ITOPCONTROL -( MODULE

I I

G302

LEFT ( WASHER

I I I

FRONT ( FOG (LIGHT - IRELAY

I I I

(HEATER

I I I

A I

CHIME ( MODULE I

I I I

Y I I

-(SWITCH_

,I I ,Y

I I I

WIPER ( MOTOR I

I _II

I I

INSTRUMENT ( CLUSTER ( (1997) I

I I I y-

I I I

STARTER ~ IIMMOBILIZER rt (SWITCH -((1997)

DIMMER

_ (

I I I

HIGH IBEAM (LIGHT _IRELAV

I I

-I_

ELECTRONIC I IMMOBILI2ER (CONTROL MODULE

q Do OBDII NNNECToR(199fi)

F I Y

I I

CASSETTE BOX LIGHT

BRAKE (LIGHT I SWITCH

WIPER/ ( WASHER (SWITCH I

I I

.~.

1/ t

LEFT ) FRONT AVXILIAflV TURN LIGHT

_(JET

HAZARD ( FLASHER IRELAY

I I

LIGHT ( SWITCH I

I I

(

7 BLOWER I RELAY I

_ II_ _ I 3

WIPER/ I WgSHER (MODULE (LOWIV L-1 I I

t I I

INSTRUMENT ( CLUSTER I

I I I

RIGHT ) FRONT AUXILIARY TUR N L IG H T

G202 890fi9

WIPER ( RELAY ((CANADA) ((1997)

G303

LOW IBEAM (LIGHT -IRELAY

I I

(HEATER -((1897) 1

I I

:THROTTLE THROTTLE

Y UNLOADER I RELAV I

G203

BRAKE ( FLUID ILEVEL

RIGHT (WASHER (JET (HEATER

I I I

7 f-1996 BFN ONLY

-I

I I I

IGNITION ( SWITCH I I

HORN ( SWITCH I I

I I I , J.

ELECTRICAL WIRING DIAGRAMS

ELE-46

Ground Distribution

1996-97 Except 318ti (2 of 5) (

I I I

BODY ELECTRONICS (CONTROL (MODULE (ZKEIV)

I I

(

RELAY 'MODULE I

I ( I _I

REAR LIGHTS (RELAY

I I

INERTIA SWITCH

(

I L-1

TR U NK LID (MICRO -(SWITCH

(

PASSENGERS ( MAKEUP

(MIRROR SWITCH

CONVERTIBLE 'TOP (STORAGE LID LOCK - MOTOR

I I

FRONT I DOMELIGHT/ ( MAP READING --I ASSEM LY

II I

-1997 ONLY

DRIVERS (MAKEUP MAKEUP

_ (SWITCHl

irl ... .

I L-1

PASSENGERS (WINDOW ( MOTOR

SPATIAL 'SOUND (SWITCH

1996 ONLY SUNROOF 'CONTROL (ASSEMBLY

I L-1

LEFT FOOTWELL (LIGHT

I I_

PASSENGERS SIDE (MIRROR

I I

-1 FIGHT RIGHT ( LIGHT

L-1 1

0:1

It f- " ----- t +----_f- ;----__+-0-- " _-----0-+---___ " - " --__--+_f-___-1

'S EATBACKRS (HEATER

'SEAT HEATER

CID (CHANGER I

PASSENGERS (DOOR (JAMB SWITCH L-1 I'

I I

PASSENGER5 'SEAT (CONTROL (SWITCH -

I I

LEFT 'FRONT ( SPEED I SENSOR

ABS F-'ELAY . I ( (1996) I _ I

RIGHT 'FRONT ( SPEED SENSOR (

I-

- M3

L-1

I I_ _

24I

1991

411

191 I:

I I I

29'M2

2zT I

A .S (HYDRAULIC ( UNIT

I I

LEFT 'FRONT ( SPEED ( (1997318) 3

F 1998 ONLY

. . m

ALL1996, 1997328,M3

1997 WIA65

¢I

1996 W/ABS

¢I

199651997 W/ASC

G202

CRUISE ' CONTROL (MODULE

INSTRUMENT ' CLUSTER I

I I

WIPER/ ' WASHER ( MODULE

I I I

2 O

21 O

- ((CANADA) 25

24 (7

BODY ( ELECTRONICS (CONTROL MODULE _(

( I I

CRASH I CONTROL ( MODULE

w.- " -0 -

O I WIPER/ WASHER ( MODULE

I I

I I I

I (USAII1)

I 1ST

2'(

I ON BOARD COMPUTER ( TEMP SENSOR (

THERMOSTAT ' (1997) I

I I

TRANSMITTER ( MODULE I

I _I O

I I I

RISE I CONTROL ( ACCTUUATOR I

---___f-t-----0-t------W-i----- . w- --t ------

t 89070

_ I

I I

GROUND

I I

RIGHT ( FRONT ( SPEED

I -I (1997318)

W/ASC

SLIP 'CONTROL ( MODULE J

I-

ABS PUMP ( MOTOR ( RELAY

22 318

I _I

L-1

I _I

F 318,328

( DRIVERS DOOR ( HANDLE SWITCH

DOOR ' LOCK I HEATER

SLIP 'CONTROL ( MODULE

I I

-____i 17

ABS 'CONTROL ( MODULE/ _ _ I UNDRALIC_

I I (

SLIP 'CONTROL ( MODULE

I `I

I I

L-1

I I I

DRIVERS ' WINDOW I MOTOR

I I

I-

( MIRROR CONTROL ( SWITCH

I_I

( DRIVERS SIDE ( MIRROR

I I

ELECTRICAL

WIRING

DIAGRAMS

ELE=47

Ground Distribution

1996-97 Except 318ti (3 of 5) I

F-_ _ )1 IGNITION I COIL I SHIELD

(HEATED OXYGEN (SENSOR

ENGINE (CONTRL_ (MODULE - (DIVE)

(

HEATED (OXYGEN SENSOR SHIELD

_-~ CAMSHAFT ( POSITN_ _ SENSOR --~ SHIELD

ICHANGE

I I

( VALVE

F---~ CRANKSHAFT POSITION/PPM __ SENSOR SHIELD

(PUMP (

I I

CONTROL (MODULE I(DME)_

I I

F--- HEATED I OXYGEN I SENSOR2 -SHIELD

HEATED (OXYGEN ISENSOR2

CAMSHAFT I POSITION SENSOR SHIELD

I --

CRANKSHAFT POSITION/RPM SENSOR SHIELD

I -O

mI ---- -- -- -- -- -----

I I I

(ENGINE CONTROL (MODULE - (ONE)

(VARIABLE

I I

SENSOR( (SHIELD

I CCONTROL

_ (SENSOR(

84 NCA

_-~ SENSOR1 SHIELD

I I

(VARIABLE ( CAMSHAFT CONTROL ISENSOR2

SENSOR2 SHIELD_

1II5 I (HOT FILM I ( AIR (MASS I _ METER -

(

FUEL PUMP/ (START ( IDENTIFICATION _ (RELAY

SENSOR2 VARIABLE - ( SHIELD I CAMSHAFT (CONTROL <1-_-~ (MODULE (VANCE)

I 1

BR=m

DATA INK CONNECTOR 19

~BR~N RN/O PG B~

G103 (1996) (M3 CANADA)

( COIL

CVL1 IGNITION

(

I I

( CVL3 IGNITION

( COIL

( CVLE IGNITION

IGNITION COIL

I I

i I

( COIL

IGNITION I i COD.

ENGINE ( CONTROL ( MODULE (DME) _I

IGNITION ( COIL SHIELD

_ __

I I ---

I IGNITION I COIL

I I

ENGINE ( ECONTROL (ODULE M - j (DIVE)

r I

RESISTOR

TRANSMISSION ( CONTROL ( MODULE _I(EGS)

28 O ¢O

I I

I ENGINE CONTROL (ODULE M - I (DIVE)

G123 (1996) (328 CANADA)

G,19 (328, M3)

IGNITION COIL SHIELD

CRANKSHAFT POSITN/_ RPMSENSOR SHIELD

SECONDARY I AIR PUMP ( RELAY

I I I

L _I Y

u _

DELAY ( RELAY ( (1996)

I I m)

ENGINE ( CONTROL ( MODULE

SOLENOID ( VALVE ( (1996) -I

341 UNLOADER (VALVE ( (1997)

I I

( TRANSMISSION CONTROL ( MODULE _ I(EGSI

I I I _

__J(OME) I_ __ Y 4/ 32/ 34/

AIR ( PUMP ( (1998)

I I_ - I

F I

26 I

(ENGINE CONTROL ( MODULE (DME) _I

I I

zBY

j .123 (328, M3) 8907 1

-I ¢I

BRN/ORG

HOT ( FILM ( AIR (MASS _ METER

I I

HOT ( FILM ( AIR MASS I v-(MATS I i

O DATA LINK CONNECTOR ,9T

DATA LINK CONNECTOR

ELECTRICAL WIRING DIAGRAMS

ELE-48

Distribution

Ground

1996-97

IGNITION COIL SHIELD

I ___

( I 1

(

TRANSMISSION CON TROL ( MODULE I 11"S)

I I_____y y_

I ENGINE CONTROL ( MODULE j (DIE)

_ --

3ar

318ti

I UNLOADER RELAY ( (1997)

(HALL EFFECT ( CAMSHAFT (SENSOR

I I I

(HOT FILM ( AIR MASSS 1 METER 1r (1996 )

F--- CRANKSHAFT POSITION _ SENSOR SHIELD

r I I 1

3 B'f 28 1 . .'r

Except

1 I

'CYL1 IGNITION ( COIL

I .T

I 21" CYL2 I IGNITION I COIL

DATA LINK CONNECTOR

IOYL3 IGNITION ( COIL

DYLa I IGNITION I COIL

I I

BET 26~

1 AIR PUMP

997 ONLY

1996 __~ONLY

PASSENGERS (DOOR (JAMB

I---

PASSENGERS ( SEAT (CONTROL

RIGHT REAR ( INTERIOR

PASSENGERS (SEAT (HEATER

I I

RIGHT REAR ( WINDOW

I I

PASSENGERS I SEATBACK (HEATER

RIGHT REAR ( INTERIOR

GROUND (318)

GI 9 (318)

G123 (318)

SUPPRESSION ( FILTER I

I I

DRIVERS ( WINDOW (MOTOR

I I

DOOR ( LOCK (HEATER

DRIVER ( DOOR (HANDLE

CD CHANGER

1 G302 (1996)

G313 (4 DOOR)

( I

ROLLOVER SENSOR

I I

CONVERTIBLE ( TOP ( ACTUATING SWITCH

---

I I I

(

CONVERTIBLE TOP I OONTROL MODULE -(

I I I

(

CONVERTIBLE TOP-END ( POSITION

-( SWITCH

---

CONVERTIBLE ( TOP ( POSITION

---( SWITCH

WINDSCREEN I CoWLPANEL ( LOCK

SEAT ( OCCUPANCY 1 DETECTOR

¢~

_I 2

I I 1

PASSENGERS ( WINDOW I MONITIORING SWITCH - ( (1997)

I I

-I 3 ,I

G202

' DRIVERS WINDOW I MONITIORING I I - . ( SWITCH -- (1997)

LEFT ( REAR ( DOOR CONTACT L-1 I I

PASSENGERS I ( SIDE ( IMPACT I I V I SENSOR -- (1997)

I I

ANTI( THEFT ( CONTROL MODULE -I

DRIVERS ( SIDE ( IMPACT I SENSOR -(1997) v

I I I

RIGHT ( REAR ( DOOR CONTACT -I

I I I 1

I I 5I

DRIVERS ( SEATBELT I SWITCH

I I I

PASSENGERS ( SEATBELT ( SWITCH I

-I 1

PASSENGERS ( SEAT T HEATER SWITCH _I

I I I 4

I I

DRIVERS ( SEA T ( HEATER -( SWITCH

I Y

-___-___0_-t--__--_ .,---0__--_---`__ .,-_--_-_-*_--0 .-____-

1 'o~ t G302 (1996)

89072

W/STEREO 6SPEAKER SYSTEM

-I 9

W/HIFI . TENSPEAKER SYSTEM

RADIO

-I 31

HIFI AMPLIFIER

G203 (1996)

CHECK ( CONTROL ( MODULE

,-( SWITCH

, .------- ..W_-*---___--7-----__-41"- ----___--0-f---_---7

I I 1

(

ELECTRICAL

Ground

1996-97

TELEPHONE I I CEIVER (1996) (

I I __ 31'

CONVERTIBLE TOpSTORAGE I LID MICRO ( SWITCH

I I I

17Y

RIGHT REAR I BRAKEPAD I SENSOR

I I

I _I

318ti

RIGHT )LICENSE LIGHT

(

I I

F __ f ____

CONVERTIBLE I TOP (CONTROL - I MODULE_

I I

DRIVERS

-1 FUEL IPUMP

I I

DRIVERS I SEAT

( SWATCH

( HARD

I I

1997WITHm CONVERTIBLE

I I I

~--' T AIL

RIGHT BACK-UP LIGHT

(

RIGHT ) BRAKE LIGHT

L_-~- ___________J r

ALL OTHERS

I I

RAR ( WINDOW

I I

SUPPRESSION ( FILTER I (2 DOOR)

I I

( BLOWER -I

Iy,-I (1BR~1 cT

i I I

I I

DRIVERS ISEATBACK ( HEATER I

I I I

) REAR TURN LIGHT

(

) REAR FOG LIGHT

LEFT TAIL LIGHT

LEFT ) TAIL LIGHT

LEFT BRAKE LIGHT

(

LEFT BACK-UP LIGHT

2 I OHANGER ( (1997) I

I I I

( INTERIOR LIGHT - (

PASSENGERS ( DOOR i JAMB I SWITCH

LEFT ( REAR

I I

I _I I

(REAR (DOOR

2 DRIVERS ( SEAT ( HEATER

RIGHT ( REAR ( INTERIOR LIGHT

I I

DRIGHT I EFOGGEfl

(

I I

iASSEMBLY

_ \

RIGHT

, RIGHT ITRUNK

RIGHT

- ~FOGR LIGHT

I I I

(SUPPORT I MOTOR/VALVE (1996)

REAR TURN LIGHT

-I SWITCH

FIGHT

I REAR WINDOW (BLOWER

( REAR ( INTERIOR - I LIGHT

(CONNECTOR(

DRIVERS I LUMBAR

___ _ _ _ _ _ _ _ _ _7RAN5-

----- -

V I

ELE-49

LEFT LICENSE LIGHT

_-_---

LEFT I REAR (INTERIOR - I LIGHT

I i

IJAMB SWITCH

LUGGAGE COMPARTMENT TELEPHONE CONNECTOR (1997)

DIAGRAMS

Distribution

Except

CENTRAL ( LOCKING ( SWITCH

WIRING

I I

I HIGH LEVEL

I LIGHT

LEFT TRUNK LIGHT ASSEMBLY

I I

I ml

IT-PD

- iCONNECTOR1

1 G312 (CONVERTIBLE)

MULTI( FUNCTION I CLOCK

I I

_I I _ I

HEADLIGHT/ I FOGLIGHT ( CLEANING MO _ I 1996) LE (CANADA) g~

HAZARD I SWITCH

I I I_

0312

(

RADIO

I_ _

ENGINE ( ( SHOWIODTC H

I I

SWITCH

I I

SERVOTRONIC ( CONTROL ( MODULE mI

I I

CHARGING ( SOCKET I

I I

CENTER CONSOLE TELEPHONE

TRANSMISSION

( INDICATOR

( LIGHT

(

m GLOVE ( BOX (LIGHT

(

I I

I _(196) I_

Gy I

m ON-BOARD (COMPUTER (() 1996

-I

FINAL STAGE UNIT

I I

INTENSIVE IWgSH I PUMP

I I I I

WIPER/ ( WASHER ( SWITCH - ( (1997)

mI 1 G203 69073

SRN

AS C I SWITCH I

I I I

WIPER/ ( WASHER ( MODULE -( (1997)

I I

I I _I

FRONT I CIGAR I LIGHTER _I

I I I

PROGRAM ( SWITCH I (W/EGS) _ I

_ Y

\ FRONT LG HT AY

REAR

RAY LIGHT

-, FRONT GAF -'LIGHTER LIGHT

CASSETTE 6 GHT (1997)

AUTOMATIC (CLIMATE (CONTROL - I MODULE

1997 W/IHKA OR ALL1996 _-__41,_ -F_---_-0-9-_----f--f----0--0_----_f-f--_----___-----

I I I

B LOWER I MOTOR I

ELECTRICAL WIRING DIAGRAMS

ELE-50

Ground Distribution 1998 Except 318ti (1 of 4)

I-

____RIGHT (

~LEFT

,HEADLAMP I LEFT ) PARK I I ( i LIGHT I I Y I 1--HEADLIGHT/ _ RIGHT I )FRONT I ( I HIGH I SWITCH ( HIGH I I I IHORN WASHE HT TURN I "-' RIGHT I , BEAM I , I , R ( BEAM , LIGHT I I LIGHT I I I LIGHT I I PUMP LIGHT_ ( ) FOG I_ -I ( _ I L---- _ I ( LIGHT

RIGHT ) PARK LIGHT

(HEADLAMP

I INTERMEDIATE IPRESSURE - ,SWITCH

I I

' WASHER FLUID LEVEL - ,SWITCH

I I I

I RIGHT

LOW (BEAM - (LIGHT

I I J

I I

~ ANTII I THEFT I' HORN

I ENGINE

I I I

COOLANT

( LEVEL

I I

SWITCH

¢t

LEFT LEFT REAR I REAR POWER ,POWER I WINDOW WINDOW I SWITCH SWITCH 3T 19T (4AD00R) (ATCONSOLE) q 0 (AT DOOR/

I I

RIGHT I REAR POWER ,WINDOW I -- SWITCH (ATCONSOLE) I

CENTRAL ( POWER (WINDOW SWITCH

I I _,

( 4

(

3'f

I I

LEFT HORN

LEFT I LO W (BEAM - (LIGHT

I I I

RIGHT ( FRONT (SPEED SENSOR

I I_

(

``77'' 1II

011

PASSENGER'S II POWER I WINDOW I I SWITCH _I

, I

AU%ILIARV FAN I MOTOR

I I

¢~

I I I

CHILD I PROTECTION (CONTROL (AT CONSOLE) _I

I I

DRIVER'S ( POWER (WINDOW SWITCH

I I I

LEFT )FOG LIGHT

(

LEFT FRONT I SPEED _ SENSOR

SLIP CONTROL (MODULE j (WIASC)

-323.328 . M2

19/x" 318

I ABS

I I

CONTROL I MODULE/ HYDRAULIC I UNIT (WIASS)

2 T

323, 1- 328, M3 WIASC

G203

G300

LEFT IWgSHER ,JET (HEATR_

I I

FRONT FOG (LIGHT

I I I_

I pIGHT WASHER JET - ,HEATER

I I

WIPER ( MOTOR I

I ,

BRAKE FLUID (LEVEL -(SWITCH

, I I_RELAV

(STARTER IMMOBILIZER SWITCH - I

I I I

I , I

(HIGH BEAM ,LIGHT -IRELAV

_ (

"' dl

LOW ( BEAM (LIGHT -IRELAV q

LEFT FRONT AUXILIARY TURN IGHT

WIPER, (WASHER (MODULE I(LOWIU -

I I I l

(BLOWER RELAY I

( I

_IMODULEL -

IHA2ARD FLASHER IRELAV

I I

G904

CHIME I MODULE

10441 2

INSTRUMENT I (CLUSTER II(323,328, I-- -I (WIASC)

I-_-I

I I

CONVERTIBLE ITOPCONTROL (MODULE

SUPPLEMENTAL ( RESTRAINTS I IBYSTEM I

I I

UNLAY OADER ( REL I _I

BRAKE ( LIGHT SWITCH

I I I

! _I

DIMMER

RIGHT ) FRONT AUXILIARY ff TURN LIGHT

I I I

INSTRUMENT ( CLUSTER I

I I

LIGHT ( SWITCH I I

7T ( ogoH CONNECTOR

ELECTRONIC I IMOaLZER_ CONTROL MODULE

I I I

GEAR ) SHIFT LEVER INDICATOR

'WIPER/ WASHER ,SWITCH

IGNITION ( SWITCH I

I I i

12 m

,HORN I -- SWITCH I I I

ELECTRICAL

Ground

1998

I I I

PASSENGER'S ISEATBACK ( HEATER

( I I

_I Y

_I v

I I

ABS ( HYDRAULIC ( UNIT

ELE-51

LEFT (F ( SPEERONTD I I (SENSOR -- (318)

ABS ( PUMP (MOTOR RELAY

318ti

DIAGRAMS

Distribution

Except

PASSENGER'S SEAT (CONTROL SWITCH

I I

IPASSENGER'S DOOR (JAMB SWITCH

PASSENGER'S (SEAT (HEATER

WIRING

_( ¢l~

L_I

I ( DRIVER'S

RIGHT ( FRONT (SPEED (SENSOR 1318)

I I

DRIVER'S ( SIDE ( MIRROR

I I

I ( DOOR LOCK

WINDOW (MOTOR

I I

I I DRIVER'S

MIRROR ( CONTROL ( SWITCH

I I

(HEATER

1G202

BODY ( ELECTRONICS (CONTROL

I ZKEIIV)

I I I

SUNROOF (CONTROL (ASSEMBLY

I I

iPASSENGER'S MAKEUP (MIRROR - (SWITCH

CONVERTIBLE (TOP (STORAGE

I _(MOTOR

FRONT I D0 ME LIGHT/ (MAP I READING ASSEMBLY

I I

PASSENGER'S (WINDOW (MOTOR

I DRIVER'S MAKEUP (MIRROR - I SWITCH

PASSENGER'S ( SIDE (MIRROR

I l

TRUNK (LID (MICRO (SWITCH

LEFT I FOOTWELL (LIGHT

RELAY (MODULE

TOP I HIFI (SWITCH

RIGHT FOOTWELL I LIGHT

I I

-__________F_____ 1

G203

( SEAT OCCUPANCY ( DETECTOR -I

I I

( LEFT REAR

I _I

( DOOR CONTACT

I I

PASSENGER'S I ,' . SIDE

( C EC C HONTRO KL ( MODULE

( ANTITHEFT ( CONTROL I MODULE

I I I

DRIVER'S

( RIGHT REAR ( DOOR I CONTACT I

I - (SIDE I ( IMPACT I _ I SENSOR

( IMPACT SENSOR

I ¢I

I I

I I I

PASSENGER'S (SEATBELT ( SWITCH

DRIVER'S ( SEATBELT ( SWITCH I

I ( DRIVER'S

8 1

-I

( PASSENGER'S SEAT ( HEATER - I SWITCH

SEAT ( HEATER - I SWITCH

KI m ¢I __t_______t__0-_______-*__ -y_ ________-0

I _ _*_______

1 G300

CRUISE (CONTROL (MODULE

_ =Y

___J `( I3Y

2I 1

INSTRUMENT (CLUSTER I

I I

247 (CRASH CONTROL (MODULE

I I

(BODY ELECTRONICS ( CONTROL - I MODULE

I I I

5Y I WIPER/ I WASHER I I MODULE I- _ I (LO W I I)

FI I I _I

THERMOSTAT

sY ION-BOARD COMPUTER I TEMP SENSOR _I

I I

G203 10441 3

-I

I I

¢ I

OBDII CONNECTOR BY

3Y O CRUISE I CONTROL ( ACTUATOR

-1 I

TRANSMITTER I MODULE I

I I

CLUTCH I SWITCH

DOOR ( HANDLE _(SWITCH

ELE-52

ELECTRICAL WIRING DIAGRAMS Ground

1998

TRANSMISSION ( CONTROL MODULE (EGS)

(

I I

-J 211

311 IGNITION ( COIL SHIELD

ENGINE ONTROL MODULE - j (DME) Y

Y 11

(I _I

Y 21

I I

UNLOADER RELAY

( _II

HALL EFFECT CAMSHAFT (SENSOR

I I

( I _I

SECONDARY AIRPUMP RELAY

CRANKSHAFT POSITION __ SENSOR -SHIELD

318ti

Except

I I

Distribution

HOT FILM MIASS METER

I I I

(( _I

_0-4

SECONDARY -,SECONDARY

( RELAY

- 5 SHIELD NSOR

41 '

ENGINE ICONTROL MODULE j (DME) 321

34Y

UNLOADER ( RE LAY

II I I v ( COIL SHIELD

G725 (318)

IGNITION

IGNIT

( COIL

w-- .4----- + --f_--

G103 (318)

CRANKSHAFT POSITION/

CYL3 IGNITION COIL

( IGNITION COIL

I 2Y

IiI .-4"-4-4----_--f-t

I I

DATA LINK CONNECTOR

( ( I

CYL1 IGNITION COIL

ENGINE ( CONTROL MODULE (DME)

( (

I I 28

I I

TRANSMISSION (CONTROL MODULE (EGS)

( I

HOT (FILM AIR

DATA LINK CONNECTOR

Q m

( Y

( METER

BRNIOR

G103 (323,328. M3)

CYL1 ( IGNITION I c01L I

I I I

CYL3 ( IGNITION

( COIL I

I I 2 /

2T CYL I IGNITION I COIL

I I I

-I

CYLS ( IGNITION ( COIL I

I I I 2Y

ENGINE ( CONTROL

I I I

( MODULE ( (DME) SET

( ROLLOVER SENSOR I I

I I

~ -I

I I

( SWITCH

CONVERTIBLE O I TOP I ACTUATING m --- I SWITCH

-I

-,-----+- ----_ f--*-----i m

I CONVERTIBLE Top I CONTROL - I MODULE

I I

( LOCK

I SW "CH 2Y

I --I

I WINDSCREEN COWLPANEL

I I I

( IGNITION ( COIL

11 1

I IGNITION ( colt

CONVERTIBLE ( TOP END ( POSITION

I I

I y

I CONVERTIBLE TOP I POSITION MICRO- I SWITCH

I I

RESISTOR 24D OHM

1 G203

G125 (323,328 .M3)

I I

PASSENGER'S ( DOOR ( JAMB -( SWITCH

:Y HIFI ( AMPLIFIER I

I I I

I I

-I

RADIO

AIR ( PUMP I

I I I

I--I I

IGHT ( REAR (IRNTERIOR -) LIGHT

zlt

1134414

PASSENGER'S ( SEAT ( CONTROL -( SWITCH

I I

PASSENGER'S ( SEAT ( HEATER

I I

__ I I I

G202

GROUND

G310 (4 DOOR)

PASSENGER'S I SEATBACK ( HEATER -I

2Y RIGHT ( REAR (POWER

L-1 SWITCH ¢t

(ATDOOR)

I I I

RIGHT ( REAR (INTERIOR LIGHT _I

SUPPRESSION ( FILTER I

I I

-I

2Y I I I

REAR ( DEFOGGER I -I

ELECTRICAL WIRING

Ground

1998

(

RIGHT ( FEAR INTERIOR ( ( LIGHT I

---

FUEL PUMP

I I ~

LUGGAGE COMPARTMENT TELEPHONE CONNECTOR

CENTRAL LOCKING ( SWITCH

LEFT LICENSE LIGHT

DRIVER'S DOOR (JAMB SWITCH I

(

318ti

( LEFTREAR INTERIOR ( LIGHT

I--I I

ELE-53

Distribution

Except

( _ I_

RIGHTREAR I BRAKE PAD ( SENSOR

I I

DIAGRAMS

DRIVER'S ( SEAT ( LUMBAR SUPPORT ( MOTORIVALVE

I--I

3/~

RIGHT ) LICENSE LIGHT

I I

RIGHTTRUNK -_------_IGH-T_SSE=BL= I I I I

(

RIGHT ) REAR TURN LIGHT

I DRIVER'S SEAT (CONTROL SWITCH _I

_ (

(

RIGHT )REAR FOG LIGHT

RIGHT TAIL LIGHT

(

RIGHT ) BACK-UP LIGHT

(

~' -

gIGHT ) TAIL LIGHT

I I

RIGHT )BRAKE LIGHT

I I

L_ ¢~

I I

CONVERTIBLE ( TOP I CONTROL - ( MODULE

I I I

I I

I 1

HARD ( TOP ICONNECTORI

I_ I I

RIGHT REAR (INTERIOR( LIGHT

I I

(

I I

I FEAR WINDOW I BLOWER

I I

_ _

CD (CHANGER I

I I

_ _

RIGHT_ (REAR I v (INTERIOR I LIGHT - _(

FILTER SID .

I(2DOOR) I

II I

LEFT ) FEAR TURN LIGHT

(

I I

I -I

PEAR I DEFOGGER I (2 DOOR)

I I

T -

I I

DRIVER'S I H EATBACK (EATER

(

I I

(

PASSENGER'S DOOR IJgMB SWITCH _(

I I I

CONVERTIBLE I TOP STORAGE (LID MICRO SWITCH

-v 1

(

I II

A LL O T H E RS

_ _

REAR ( DEFOGGER I

FEAR WINDOW ( BLOWER WORDH _ I SW

LEFTTRUNK

LIGHTASSEMBLV r__ _ _ _ _ _ _ _ __

WIT H CONVERTIBLE

(

LEFT FEAR ( INTERIOR LIGHT _ (

___J

"T2 DEEP)

LEFT FEAR INTERIOR - I LIGHT

MULTI( FUNCTION ( CLOCK

HAZARD ( SWITCH I

I I

GLOVE I

BIGHT I- _I

I I

CHARGING ' SOCKET

I I I

II _

I I

mI / 1 G203 10441 5

BRN

ASO I SWITCH I

TRANSMISSION ( POSITION ( INDICATOR

FINAL STAGE ( UNIT

(

I I

AUTOMATIC ( CLIMATE ( CONTROL

CENTER CONSOLE TELEPHONE CONNECTOR

WIPER/ I WASHER (SWITCH

( WIPER/ WASHER ( MODULE

I I

( PROGRAM SWITCH I(WIEGS)

REAR

CASSETTE

RAV II LIGH_'IGHT ( __ ('T B 318, 323, 328 v3 521 71 I

I I

FRONT I CIGAR ( LIGHTER

FRONT ASHTRAY L GHT

FRONT CGAR LIGHTER LIGHT

I I

LEFT ACK- UP LIGHT

_ (

LEFT ) TAIL LIGHT

LEFT BRAKE LIGHT

(

I I I I I I II

---J (2 DOOR) (4 DOOR) I I I

G312

LEFT ) REAR FOG LIGHT

L_1

__\I/

ENGINE ( HOOD ( SWITCH

LEFT ) TAIL LIGHT

(

G312

I I I I

(HARD TOP ICONNECTOR1

~%___'j

(

BLOWER ( MOTOR I

I HIGH LEVEL 1 I STOP I -) LIGHT I

DRIVER'S SEAT HEATER -I

ELE-54 ELECTRICAL WIRING DIAGRAMS Ground

Distribution

1995-96

HEADLIGHT/ FOGLIGHT WASHER PUMP

RIGHT HIGH BEAM LIGHT

WASHER PUMP

I I L -I

RIGHT PARK LIGHT

I I L-1

ANTITHEFT HORN

I I ! _I

DOUBLE TEMPERATURE SWITCH 1- 7

1 - 7

I I L -I

I I L-1

I I ! _I

RIGHT FRONT TURN LIGHT

RIGHT FOG LIGHT

PRESSURE SWITCH

1 --,

318ti

1 - 7

AUXILIARY FAN MOTOR

1 - 7

I I L -I

LEFT PARK LIGHT

F -,

I I I-_I

I --,

I I L -I

I I

I I I

ENGINE CONTROL MODULE (DME) I

I I I

I I rv

CAMSHAFT POSITION (SENSOR _SHIELD

HEATED OXYGEN ( SENSOR SHIELD

Q .1

--_ CAMSHAFT POSITION (SENSOR ___JSHIELD

CRANKSHAFT POSITION L I ( SENSOR SHIELD

I --,

(- i

SHEATED OXYGEN ENSOR

LEFT FRONT TURN LIGHT

LEFT FOG LIGHT --,

I I

I i

I I L-1

CYLINDER 4 IGNITION co,L

CYLINDER3 IGNITION COIL

RIGHT HORN

I i

I I L -I

1 ,

~ MOIDU EO(DME)OLI

I I L -I

CYLINDER2 IGNITION COIL

IGNITION COIL2 ( SHIELD

CRANKSHAFT POSITION (SENSOR ¢I _ SHIELD

DATA LINK CONNECTOR

LEFT HORN

CYLINDER1 IGNITION COIL

2I C

LEFT HIGH BEAM LIGHT

I I I I L -I L -I

G100

TRANSMISSION CONTROL MODULE (EGS)

LEFT LOW BEAM LIGHT

I I

COROL MODULE(EGS)

m ml

RESISTOR

CHIME MODULE I --, I I I _I

II,, (1995)

RIGHT FRONT AUXILIARY TURN LIGHT

UNLOADER RELAY

LEFT WASHER JET HEATER

RIGHT WASHER JET HEATER

WIPER MOTOR

BRAKE FLUID LEVEL SWITCH

WIPER RELAY

HIGH BEAM LIGHT RELAY

F -I I I

I --, I I

I --, , I

I --, I I

F -I I I

I --, I I

1 --, I I

! _I

INSTRUMENT CLUSTER

I I

FOG LIGHT SWITCH ILLUM

WIPER( WASHER SWITCH

LIGHT SWITCH ILLUM

i I

I --, I I

1__ I I

(

1_1

L-1

COMBINATION SWITCH I

BRN

BRN 1 G202

i I

CONTROL MODULE (EWSIII I I

i I I 1

(

ASS LEFT FRONT SPEED SENSOR

BLOWER RELAY

LEFT FRONT AUXILIARY TURN LIGHT

WIPER( WASHER MODULE (LOW 11)

HAZARD FLASHER RELAY

1 - 7 , I

1 - 7 I I

1 -7 I I

! _I

I I I

ASS PUMP MOTOR RELAY

i I

I ,

L -I

I I

LOW BEAM LIGHT RELAY

ASS HYDRAULIC UNIT i

I I

HI-FI AMPLIFIER I I

RADIO (PREMIUM)

1- 7 I I

RADIO (BASE)

I L-1

\1G202

1 G202

84317

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-55

ELECTRICAL WIRING DIAGRAMS

Ground Distribution 1995-96 318ti (2 of 3)

ASSSLIP CO .TPOLMOOULE

I I

ASS RIGHT FRONT SPEED SENSOR

DRIVER'S SIDE MIRROR

MIRROR CONTROL SWITCH

DOOR LOCK HEATER

DRIVER'S DOOR HANDLE SWITCH

BODY ELECTRONICS CONTROL MODULE

FRONT DOME/ MAP READING ASSEMBLY

F -,

1 -7

F -,

L-1

!._I

SWITCH SPATIAL SOUND (1996)

REAR WIPER/ WASHER INTERVAL MODULE

DRIVER'S MAKEUP MIRROR SWITCH

F -,

L-1

INERTIA SWITCH

SUNROOF CONTROL ASSEMBLY

I I

PASSENGER'S MAKEUP MIRROR SWITCH

DRIVER'S SEAT BELT SWITCH

L-1

BE .

J /4L PASSENGER'S SEAT CONTROL SWITCH

I i

PASSENGER'S SEAT HEATER

I i

I I

PASSENGER'S SEATBACK HEATER

! _I

! _I CD CHANGER

I I I _I

II iI

I _____J

PASSENGER'S DOOR JAMB SWITCH

BLOWER MOTOR

CLIMATE CONTROL SWITCH ILLUM

IRKS CONTROL SWITCH

FRESH AIR/ RECIRCULATION MOTOR

INTEGRATED HEATING/ CLIMATE CONTROL MODULE

EVAPORATOR TEMPERATURE SENSOR

i I

I I

1 I

=1 -

-Y

! _I

i I I

I =Y

MODULE

I -I

GLOVE BOX LIGHT SWITCH I

WS11)

INOT USED)

CLUTCH SWITCH

F -

L-1

! _I

ANTITHEFT HORN

BODY ELECTRONICS CONTROL MODULE

F -,

! _I

TR(

TEMPERATURE WHEEL SWITCH I I

ERT

, -I

1 I

m~ CONNECTOR (1996)

II iI

! _I

INCLUS

CRUISE CONTROL ACTUATOR (TEMPOMAT)

ON-BOARD COMPUTER (BC-LOW)

II iI

L_I

I I I -)

WIPER/ WASHER MODULE (LOW 11)

CRASH CONTROL MODULE

CRUIBECONTROL MODULE (TEMPOMAT)

MSENSORURE

I _I

HAZARD SWITCH

HEADLIGHT/ FOGLIGHT CLEANING MODULE

ENGINE HOOD SWITCH

I -i I I

I - i I I

I I

I Y

CLOCK

I _I

TRANSMISSION POSITION INDICATOR LIGHT

I I

-Y

W/ONBOARD COMPUTER BEN

REAR ASHTRAY LIGHT I

I I

FRONT ASHTRAY LIGHT

I I

CASSETTE TAPE PLAYER LIGHT

I I

FRONT CIGAR LIGHTER LIGHT

FRONT CIGAR LIGHTER

TELEPHONE EJECTBOX

F -,

PROGRAM SWITCH

DRIVER'S POWER WINDOW SWITCH

I I

BEN

F -, I I

L -I

DRIVER'S SEAT HEATER SWITCH I I

L -I

PASSENGER'S SEAT HEATER SWITCH

SUPPLEMENTAL RESTRAINT SYSTEM CONTROL MODULE

1 - 7 I I

F -1 I

L _I

-1 G201

G302 1 84318

PASSENGER'S POWER WINDOW SWITCH

G303

ELE-56

ELECTRICAL WIRING DIAGRAMS

Ground Distribution 1995-96 318ti (3 of 3)

DRIVER'S DOOR JAMB SWITCH

DRIVER'S SEATBACK HEATER

DRIVER'S SEAT HEATER

FUEL PUMP

RIGHT REAR BRAKE PAD SENSOR

DRIVER'S SEAT LUMBAR SUPORT MOTOR/VALVE

DRIVER'S SEAT CONTROL SWITCH

TELEPHONE TRANSCEIVER

1 --, 1 -F 7 I _F-

SEAT OCCUPANCY DETECTOR

I I

L -I

ANTITHEFT CONTROL MODULE

L -I

LEFT TRUNK LIGHT ASSEMBLY

1- 7 I

L -I

RIGHT TRUNK LIGHT ASSEMBLY

F-

LEFT LICENSE PLATE LIGHT

RIGHT LICENSE PLATE LIGHT

TRUNK LIGHT SWITCH

SUPPRESSION FILTER

F - F - I --, 1 --, 1 - 7

CENTRAL LOCKING SWITCH (1995)

L -I

!_I

L -I

PASSENGER'S SEAT BELT SWITCH

L -I

Z G404

(NOT USED)

1 G404

TRANSMISSION CONTROL MODULE(EGS)

ENGINECONTROL MODULE(DME)

IGNITION COIL SHIELD

----

_Y _TY

DATA LINK CONNECTOR

mY Y ~Y

1 G103 (1998)

84320

___

CRANKSHAFT POSITION SENSOR j SHIELD

CRANKSHAFT POSITION SENSOR SHIELD SE

HALL EFFECT CAMSHAFT SENSOR

I_~- I

ENGINE CONTROL MODULE (DME)

I I

HOTFILM AIR MASS METER

CYLINDER 1 IGNITION COIL

I-

I i

I I

CYLINDER2 IGNITION COIL

1 G131 (1996)

CYLINDER 3 IGNITION COIL

I I

CYLINDER4 IGNITION COIL

, I

i I

ELECTRICAL WIRING DIAGRAMS

ELE-57

Ground Distribution 1997 318ti (1 of 3)

HEADLIGHT/ FOGLIGHT WASHER PUMP

I i I I

RIGHT LOW BEAM LIGHT

I i I ! _I T

RIGHT HIGH BEAM LIGHT

RIGHT PARK LIGHT

I i I I ! _I

ANTIDOUBLE THEFT TEMPERATURE HORN SWITCH

I i I I !_I

I 1 I I ! _I

I 1

L__I

-T

I i I I L-1

L.-I

RIGHT FRONT TURN LIGHT

RIGHT FOG LIGHT

PRESSURE SWITCH

AUXILIARY FAN MOTOR

I i I I L -I

LEFT PARK LIGHT

I 1

L -I

L-1

LEFT LOW BEAM LIGHT

LEFT HIGH BEAM LIGHT

I i I I ! _I

I i

I 1

L -I

I 1I I L -I

LEFT FRONT TURN LIGHT

LEFT FOG LIGHT

LEFT HORN

I iI I L -I

RIGHT HORN

I 1I I L -I

I /-IGNITION OOR SH ELD

ENGINECONTROL MODULE(DME)

I I

__w_ +

G100

CRANKSHAFT POSITION SENSOR SHIELD

TRANSMISSION CONTROL MODULE(EGS)

CRANKSHAFT POSITION SENSOR ___)SHIELD

__-

HALL EFFECT CAMSHAFT SENSOR

UNLOADER RELAY

r I

I I

_a--f-*

-r__-_*____-

I I

DATA

1 I

HOTFILM AIRMASS METER

CYLINDER 1 IGNITION COIL

I I

CYLINDER2 IGNITION COIL

I I

CHIME MODULE

I i I I _I

I i I I ! _I

UNLOADER RELAY

I i ! _I

INSTRUMENT CLUSTER 1 F

I I I~ m I

BRAKE LIGHT SWITCH

I i I I I I Y

LEFT WASHER JET HEATER

INSTRUMENT CLUSTER

I i I I I I 7

I i I I I I

COMBINATION SWITCH I

I I Iz~ I

DBDII CONNECTOR

RIGHT WASHER JET HEATER

I i I I I I ~~

BRAKE FLUID LEVEL SWITCH

WIPER MOTOR

I i I I I aI

STARTER IMMOBILIZATION SWITCH

I i I

I i I I L-I Y

L -I ~Y

IGNITION SWITCH

WIPER/ WASHER SWITCH

LIGHT SWITCH ILL UM

FOG LIGHT SWITCH ILLUM

F -I I I

F -I I i

F I I

- I

Iz~ I

I I

-I

HIGH BEAM LIGHT RELAY

LOW BEAM LIGHT RELAY .

I i I I I Y

I i I I I I <Y

BLOWER RELAY

1 7 I I I I Y -

LEFT FRONT AUXILIARY TURN LIGHT

WIPER/ WASHER MODULE (LOW11)

I i I i I i I I I I I Y -

ELECTRONIC IMMOBILIZER MODULE (EWSIH

HI-FI AMPLIFIER

RADIO (PREMIUM)

RA010 (BASE)

- 7

1 --,

1- 7

F -,

SRN

BFN 1 6202

89159

CYLINDER/ IGNITION COIL

I I

1 G131 (1908)

G103

RIGHT FRONT AUXILIARY TURN LIGHT

CYLINDERS IGNITION COIL

1G202

1 G202

HAZARD FLASHER RELAY

I i I I ! _I

ELE-58

ELECTRICAL WIRING DIAGRAMS

Ground Distribution 1997 318ti (2 of 3) CRASH CONTROL MODULE

WIPER/ WASHER MODULE LOW I])

I I

PASSENGER'S SEAT HEATER

PASSENGER'S DOOR JAMB SWITCH

PASSENGER'S SEATBgCK HEATER

CD CHANGER

!_I

! _I

ABSSIIP CONTROL MODULE I

---I

INSTRUMENT CLUSTER

I I

! _____J

I I

FRONT DOME/ MAP READING ASSEMBLY

DRIVER'S WINDOW MOTOR

DRIVER'S DOOR HANDLE SWITCH

BODY ELECTRONICS CONTROL MODULE

F -,

~ _I

L -I

L-1

RIGHT FRONT FOOTWELL LIGHT

ON-BOARD COMPUTER TEMPERATURE SENSOR

L-1

DRIVER'S MAKEUP MIRROR SWITCH

I - i

! _I

L-1 r

-1

REAR WIPER/ WASHER INTERVAL MODULE I

L_I DIGITAL CLOCK

PASSENGER'S WINDOW MOTOR

HAZARD SWITCH

ENGINE H000 SWITCH

TRANSMISSION POSITION INDICATOR LIGHT

BLOWER MOTOR

F -1 , I I

1 -1 I I

F -1 I I

I- i , I

I I

( I

L_I

SUNROOF CONTROL ASSEMBLY

CLUTCH SWITCH

I I

DBDII CONNECTOR

LEFT FRONT FOOTWELL LIGHT

L_I

BODY ELECTRONICS CONTROL MODULE

I I

L_I

I I

TRANSMITTER MODULE (EWSII)

MIRROR CONTROL SWITCH

L_I

DRIVER'S SIDE MIRROR

CRUISE CONTROL MODULE (TEMPOMAT)

! _I

CRUISE CONTROL ACTUATOR ITEMPOMAT)

ON-BOARD COMPUTER (BC-LOW)

PASSENGER'S MAKEUP MIRROR SWITCH

I - i

L-1 v

L-1 ..

BRN

BRN G201

>- G201

BLOWER MOTOR

CLIMATE CONTROL SWITCH ILLUM

INKS CONTROL SWITCH

FRESH AIRI RECIRCULATION MOTOR

F -1

1 --i

F -1

F -,

F -I

! _I

INTEGRATED HEATING/ CLIMATE EVAPORATOR CONTROL TEMPERATURE MODULE SENSOR

, I

GLOVE BOX LIGHT SWITCH

TEMPERATURE WHEEL SWITCH

F -1 I

BEN

WIPER/ WASHER SWITCH

WIPER/ WASHER MODULE

FRONT

TAPE PLAYER LIGHT

CIGAR LIGHTER LIGHT

FRONT CIGAR LIGHTER

i I

TELEPHONE CONNECTOR

..Y

i I

TELEPHONE EJECT BOX 1 I

i I

ABC SWITCH I I

i I

PROGRAM SWITCH I ,

PEAR DEFOGGER SWITCH

CLIMATE CONTROL SWITCH ILLUMINATION

i I

(- i I I

I _I

! _I

I I

eRN

WITH IHKS

CASSETTE

i I v I 1 - 7 (I I I I I I -r

WITH HS

DRIVER'S POWER WINDOW SWITCH I

PASSENGER'S POWER WINDOW SWITCH

DRIVER'S SEAT HEATER SWITCH i I

PASSENGER'S SEAT NEATER SWITCH

SUPPLEMENTAL RESTRAINT SYSTEM CONTROL MODULE

1- 7 I I

AG302

1 89160

G302

.303

ELECTRICAL

Ground

1997

DRIVER'S DOOR JAMB SWITCH

DRIVER'S SEATBACK HEATER

FUEL PUMP

I --,

F -I

I I

SEAT OCCUPANCY DETECTOR F -, I I I

REAR CENTER INTERIOR LIGHT

LEFT TRUNK LIGHT ASSEMBLY

_-I

1 - 7

F -,

I --,

F -,

1 --,

-T

PASSENGER'S SIDE IMPACT I SENSOR I

I I

-T

RIGHT TRUNK LIGHT ASSEMBLY

CENTRAL LOCKING SWITCH

LEFT LICENSE PLATE LIGHT

RIGHT LICENSE PLATE LIGHT

TRUNK LIGHT SWITCH

1 --,

1 -7

I - i

!_I

L-1

L-I

L -I

L-1

-r

-T

A BS HYDRAULIC UNIT

SLIP CONTROL MODULE

ASS PUMP MOTOR RELAY

LEFT FRONT SPEED SENSOR

RIGHT FRONT SPEED SENSOR

I I

F -, I I

PASSENGER'S SEAT BELT SWITCH

DRIVER'S SEAT BELT SWITCH

DRIVER'S SIDE IMPACT SENSOR

F -I I 1

F -I I I

-T

I I

L-1

!_I

_I Y

ELE-59

TELEPHONE CONNECTOR

! _I

HIGH LEVEL STOP LIGHT

!_I

I I

CD CHANGER

! _I

ANTITHEFT CONTROL MODULE

318ti

RIGHT REAR BRAKE PAD SENSOR

DIAGRAMS

Distribution

DRIVER'S SEAT HEATER

WIRING

SUPPRESSION FILTER

REAR DEFOGGER

i I

L-1

! _I

L-1

-T

ASS CONTROL MODULE I I

I I

ELE-60

ELECTRICAL WIRING DIAGRAMS Ground

1998

HEADLIGHT/ FOGLIGHT WASHER PUMP

I I

RIGHT LOW BEAM

LIGHT

RIGHT HIGH BEAM LIGHT

RIGHT PARK LIGHT

( )

(_)

ANTITHEFT HORN

DOUBLE TEMPERATURE SWITCH

! _I

I I

PRESSURE SWITCH

I I

! _I

I }

- ___

RIGHT FRONT AUXILIARY TURN LIGHT (

)

UNLOADER RELAY

RIGHT FOG LIGHT

RIGHT FRONT TURN LIGHT

( )

AUXILIARY FAN MOTOR

I I

LEFT LOW BEAM LIGHT

LEFT PARK LIGHT

1 I

LEFT HIGH BEAM LIGHT

LEFT HORN

I I

LEFT FRONT TURN LIGHT

LEFT FOG LIGHT

I I

TRANSMISSION CONTROL MIDUL=(-G-)G-

I Y

HALL EFFECT SECONDARY CAMSHAFT AIRPUMP UNLOADER SENSOR RELAY RELAY

DATA L CONNECTOR IN'

°f

BRAKE LIGHT SWITCH

1 I

I I

HOTFILM AIRMASS METER

CYLINDER/ IGNITION COIL

I I

HIGH BEAM LIGHT RELAY

CYLINDER2 IGNITION COIL

I I

LEFT WASHER JET HEATER

RIGHT WASHER JET HEATER

WIPER MOTOR

BRAKE FLUID LEVEL SWITCH

STARTER IMMOBILIZATION SWITCH

I I

1 I

- I

HORN SWITCH I I I

I I

I i

I I

I I I

I Y

LOW BEAM LIGHT RELAY

CYLINDER 4 IGNITION COIL

I I

I I I

LEFT FRONT AUXILIARY TURN LIGHT -

BLOWER RELAY

I 1

«T

)

(

WIPER/ WASHER MODULE (LOW II)

I I - I

COMBINATION SWITCH I I I

IGNITION SWITCH

I I I

oeDN CONNECTOR

I I

WIPER/ WASHER SWITCH I

I I

FOG LIGHT SWITCH ILLUM

LIGHT SWITCH ILLUM I

I I

I I I

I I

ELECTRONIC IMMOBILIZER MODULE (EWSIN I I I

I I I

SUBWOOFER I I

I I

BRN

HI-FI AMPLIFIER

1 I

I I

RADIO I I

I I

_W1 .11, SYSTEM

BRN 1 G202

HAZARD FLASHER RELAY

I I

SUBWOOFER W'

104443

I I

CYLINDERS IGNITION COIL

RIGHT HORN

_________~_~~

INSTRUMENT CLUSTER

GIBD

POSITION SENSOR SHIELD

ENGINECONTROL MODULE(DME)~___~CRANKSHAFT Z POSITION SENSOR SHIELD

I I I I I I

318ti

f== ;~ CRANKSHAFT

IGNITION COIL SHIELD

CHIME MODULE

I I

Distribution

16202

ELECTRICAL WIRING DIAGRAMS

ELE-61

Ground Distribution 1998 318ti (2 of 3) CRASH CONTROL MODULE

I I

PASSENGER'S SEAT PASSENGER'S CONTROL SEATBACK SWITCH HEATER

! _I

PASSENGER'S DOOR JAMB SWITCH

! _I

CRUISECONTROL MODULE (TEMPOMAT)

! _I

DRIVER'S SIDE MIRROR

MIRROR CONTROL SWITCH

DRIVER'S WINDOW MOTOR

BODY ELECTRONICS CONTROL MODULE

FRONT DOME/ MAP READING ASSEMBLY

I I I

I I I I L-1

I I I I I _I

I I

I I I

RIGHT FRONT LI GHTLL

(

)

(

CRUISE CONTROL ACTUATOR (TEMPOMAT)

BODY ELECTRONICS CONTROL MODULE

CLUTCH SWITCH

F -

1 --,

1 - 7

1 --,

LEFT FRONT `°LWELL LIGHT

WIPER/ WASHER MODULE LOW 11)

TRANSMITTER MODULE (EWS11)

INSTRUMENT CLUSTER

F ----- i

I I

PASSENGER'S SEAT HEATER

BOARD COMPUTER (BC-LOW)

)

i~ON-BOARD ° COMPUTER TEMPERATURE SENSOR

I I

OBDD CONNECTOR

i _I

¢O

DIGITAL CLOCK

I I

SUNROOF CONTROL ASSEMBLY

REAR WIPER/ WASHER INTERVAL MODULE

DRIVER'S MAKEUP MIRROR SWITCH

PASSENGER'S WINDOW MOTOR

I L -I

I I I I L -I

I I I I L-1

I I I I 1-1

I I I I L-1

HAZARD SWITCH

ENGINE HOOD SWITCH

TRANSMISSION POSITION INDICATOR LIGHT

F I I

F -, I I

FOLDING SUNROOF COMFORT RELAY

I I I I ! _I

FOLDING SUNROOF SWITCH

I I

PASSENGER'S MAKEUP MIRROR SWITCH

i I

I I ! _I

IBRN

BRN

>- G201

BLOWER MOTOR

CLIMATE CONTROL SWITCH ILLUM

IHKS CONTROL SWITCH

FRESH AIR/ RECIRCULATION MOTOR

I - i I I

1 --, I I

1 - 7 I

1- 7 I I

I_I

! _I

WIPER/ WASHER SWITCH

WIPER/ WASHER MODULE I

I I

INTEGRATED HEATING/ CLIMATE CONTROL MODULE

I!_I

EVAPORATOR TEMPERATURE TEMPERATURE WHEEL SENSOR SWITCH

i I

I I

! _I

FRONT CIGAR

FRONT CIGAR LIGHTER

i I

ABC SWITCH I

GLOVE Box LIGHT SWITCH I

i I

! _I

DRIVER'S POWER WINDOW SWITCH

PROGRAM SWITCH

(-) _I !_I I!_I !_I

SPIN I -1 G201

104444

TELEPHONE CONNECTOR

I I

PASSENGER'S POWER WINDOW SWITCH I

I ! _I

I/t G302

DRIVER'S SEAT HEATER SWITCH

! _I

BLOWER MOTOR

REAR DEFOGGER SWITCH

CLIMATE CONTROL SWITCH ILLUMINATION

F I I

I --, I

«7

PASSENGER'S SEAT HEATER SWITCH I

! _I

SUPPLEMENTAL RESTRAINT SYSTEM CONTROL MODULE

I ! _I

1 t

I 1

G302

G303

ELE-62

ELECTRICAL WIRING DIAGRAMS

Ground Distribution 1998 318ti (3 of 3)

DRIVER'S DOOR JAMB SWITCH

DRIVER'S SEATBACK HEATER

I I

FUEL PUMP

DRIVER'S SEAT HEATER

CD CHANGER

(

I I

I_I

RIGHT REAR BRAKE PAD SENSOR

DRIVER'S SEAT CONTROL SWITCH

HIGH LEVEL STOP LIGHT (

I I

)

CONNECTOR

L-1

REAR CENTER INTERIOR LIGHT

I I

LEFT TRUNK LIGHT ASSEMBLY

L-1

RIGHT TRUNK LIGHT ASSEMBLY

! _I v

CENTRAL LOCKING SWITCH

(

I V

LEFT LICENSE PLATE LIGHT

RIGHT LICENSE PLATE LIGHT -

TRUNK LIGHT SWITCH I

I I

I Y

ANTENNA AMPLIFIER I

I I

I V

REAR DEFOGGER I

I I

I Y

G404

SEAT OCCUPANCY DETECTOR

I I

I~I

ANTITHEFT CONTROL MODULE

I I

PASSENGER'S PASSENGER'S SIDE SEAT IMPACT BELT SENSOR SWITCH

I I I I _r

I=~I

I I I I r

ABS PUMP MOTOR RELAY

LEFT FRONT SPEED SENSOR

RIGHT FRONT SPEED SENSOR

F -, I I

F -,

F -, 1 1

1 _I

ASS HYDRAULIC UNIT

-r

I ?~

G202 (W/ASS)

1 I m~

I 1

DRIVER'S SEAT BELT SWITCH

DRIVER'S SIDE IMPACT SENSOR

I I I I r

I I 'T

I II

ASS CONTROL MODULE/ HYDRAULIC UNIT I

I 1

1 I rY

RIGHT FRONT SPEED SENSOR

SLIP CONTROL MODULE r

AIR PUMP

I --, 1 1

I 1

I I

__J

-rr-Y~ Yg

0201 (WIASC)

G704

104445

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-63

Starting HOT IN RUN ANDSTART

F - i B4 JUMP START I JUNCTION POINT

RED RED

FUSIBLE LINK

RED RED

GRN/GRY L

F28 1 DISTRIBUTION BOX FUSE

RED RED 5

GRN/GRYI

BATTERY I OFF

IGNITION I SWITCH

A/TRANCE

STARTI

- ACC=RUN BRNI

I SWITCH

BLK/YEL

W/EGS)

iLO

~HJ(

BRN/BLK

W/O EGS

W/EGS

BLK/YELI

BLK/VE6~

I "~ BRN/BLKio

TRANSMISSION SYSTEM

BRN/BLK

STARTER RELAY

2 BLK/YEL

SIN I

11 BLK/YEL DATA LINK CONNECTOR

BLK/ GRN

GIN41

G202

BLK/ VEL

BLKIGRN RED RED

BLK/GRN

BLK/ GRN

1992 3181 & 318is, 1992-93 3251 & 325is

BLK/ YEL

10 I

_I ON-BOARD COMPUTER

I _I WIPER/WASHER MODULE (CANADA)

INTEGRATEDCLIMATE REGULATION CONTROLMODULE

GENERATOR

STARTER

88171

HOT IN RUN AND SRRR 7 7 TART

r --) B. JUMP START JUNCTION ---II POINT

11 u~~~,,, I

MOUNTED BATTERY W/ ENGINE BATTERY

-/TRUNK

X7183

RED

RED I

GRN/GRY

(OFF

RED 5

BATTERY

1FRONTPOWER F28 I FUSE DISTRIBUTION BOX 5A - J (W/TRUNK MOUNTED BATTERY ONLY)B 1 -

~ J

( IGNITION SWITCH

5),

STAITI

- ACC-RUN

4 BLK/YEL~

SPIN

A/TRANGE I SWITCH (W/EGS) YHJ 7

SINAILK

" BRNI TRANSMISSION WIOEGS III BOB SYSTEM .Let RN/ BLK/YEL ^ BLKIYEBLI STARTERRELAY

ON-BOARD COMPUTER 88158

1_ G202

BLK/YEL

BLK/GRN

BLK/ GRN I 0j,

4T BRNI

BLK/YELI

It BLK/YEL DATA LI NK CONNECTOR

BLK/ GRN(

2T BLK/YELI

I I _I

1j,

WIPER/WASHER MODULE (CANADA)

I I I _I

INTEGRATEDCLIMATE REGULATION . CONTR LMODULE

BLKIGRN RED RED

~ 1I I

I -) GENERATOR

BLK/ YEL

1993 3181 & 318is

ELE-64

ELECTRICAL WIRING DIAGRAMS

Starting H_OT_A_TALL_TIMES

I LOCI

ACC

START( I RUN

BLK/YEL

BLK/ YEL

'~ W/EGS

B L3/1 YEL ( FUEL PUMP/START I IDENTIFICATION - (RELAY

FUSE1 DISTRIBUTIONL F28 i 5A - J

I6 GRN/GRY

BLKIYE M3 CANADA

W/O EGS

FRONTPOWER

HOTINRUNANDSTART

IGNITION ISWITCH

BLK/(

7 BRN/WHTT

YELJJJIL 6 .

BRN/WHT ~ B ,l,

2~~T //''

.,K/' YEIL

B RN

BL, K/f YEL

AUTOMATIC I TRANSMISSION RANGE SWITCH

_,I

W/O EGS

STARTER RELAY

W/EGS

BLK/YELI MICANADA

EX M3 CANADA

BILK/ YELI

POWER DISTRIBUTION

JI __I

RED

1994 Early . Production 3181, 3181C, 318is, 3251, 3251C, 325is & M3

GENERATOR

BLK/ YEL BLK/ GRN

BLK/ .RN

BLK/ GRN

.BLK/ GRN

I i I I I I 1 I ! _II ON-BOARD BODYELECT WIPE__ /WASHER INTEGRATED

BLK/ YEL DATA LINK CONNECTOR

I i I I I _I

1 I I I ! _I

COMPUTER

CONTROL MODULE

MODULE

CLIMATE REGULATION CONTROL MODULE

82687

H_OT_A_TALL_TIMES HOTATALLTIMES HOTINRUNANDSTART __ FRONTPOWER I SWITCH FUSE F26 I DISTRIBUTION BOX FUSE I 10A F2B LOCI START( 5A

---,

L______~J

GRNIGRY

S~" r ---

GRN/BL6~

GRN/WH

rI _

GRN/WHT1

BLK/YEL

------- -

BRN/BLK

I BLK/VEL

4 SAN " POWER DISTRIBUTION

CANADA BLK/YELI

RED

5 BRN

BLK/YEL

DATA LINK CONNECTOR 82689

ERIN

1994 Late Production 3181, 318iC, 318is, 3251, 325iC, 325is & M3

G202

BRN

G103

POWER DISTRIBUTION

¢I ¢

BLK/GRN

BLK/l GRN BLK/ YEL

..+++1 . FUELPUMP/START IDENTIFICATION ~RELAY

BLK/YELI

BLK/ YEL

BRN/BLK

1 STARTER TRANSMISSION (MOBILIZATION RANGE iRELAV SWITCH

2 BLK/YEL

BLK/YELI

I I ~,-{ AUTOMATIC

US~~

I I

BLK/ GRN

12~

I I

ON-BOARD COMPUTER

I I I

SODYELECT CONTROL MODULE

WIPER/WASHER MODULE

GENERATOR(

BLK/ GRN 1

I i I

INTEGRATED CLIMATE REGULATION CONTROL MODULE

ELECTRICAL WIRING DIAGRAMS

ELE-65

Starting HOTATALLTIMES

HOTATALLTIMES HOTINRUNANDSTART IGNITION -IFRONT POWER I S I ~FUSE31 I DISTRIBUTION BOX FUSE

~ RED/YE5L1

BRN

3 - r --_

AUTOMATIC TRANSMISSION RANGE SWITCH

7 BRN

U SA BLKIYEL

PJ, - ELECTRONIC -___-~~ IIMMOBILISER (CONTROL (MODULE I (EWI511)

BLK/YEL BRN

B RN/BLK "

CANADA

BLKIYEL

5 BRN

BLKIYELI

FUEL PUMP/START IDENTIFICATION RELAY

2 BLKNEL

BRN

G103

POWER DI STRIBUTION

RED

BLK/GRN

BLK/ YEL

1995-96 3181, 318iC, 3181s, 325i, 3251C, 325is, 3281, 328iC, 328is & M3

+ G202

,~ POWER DISTRIBUTION

RED

__I

GENERATOR

BLK/I GRN

1_1

ON-BOARD COMPUTER

! _I I

BODYELECT CONTROL MODULE

82715

! I

!_I WIPER/WASHE4NTE RATED MODULE CLIMATE REGULATION CONTROL MODULE

HOTATALLTIMES HOT IN RUN & START ----------------,FRONTPOWER FUSE FUSE FUSE ,DISTRIBUTION BOX

7T BRIN

HOTATALLTIMES

BLKIYEL

1997-98 318i, 3181C, 318is, 325i, 325iC, 325is, 3281, 328iC, 328is & M3

ISTAUMP

J JUNCTION POINT

BRN 1G200

RED

__I

BLK/GRN

STARTER

GENERATOR

BLK/ GRN I

BLK,( GRN

72~

I I

BLK/ GRIN

I i I

g.S

I i I

ON-BOARD BODY AUTOMATIC COMPUTER ELECTRONICS CLIMATE CONTROL CONTROL MODULE MODULE 88021

ELE-66

ELECTRICAL WIRING DIAGRAMS

Starting r _ -, BL

RED FUSIBLE LINK

HOTINRUN ANIL0START

I DISTRIBUTOR I

RED

I L

-J

FRONTPOWER F28 I DISTRIBU71ONBOX USE SA-- J

r 1 FRONTPOWER I DISTRIBUTION BOX I L~J RED

BATTERY

OFF

. START

- ACC

RUN

IGNITION I SWITCH

j 4

BLK/YEL

BRN/

BRN/BLBKI

TRANSMISSION SYSTEM (MODULE

I !

1`( / BLK/YEL/

RED

_________

1995-96 318ti

__J

7 SIRN

STARTER

M I

I GENERATOR

BLK/GRN

BRN "

BLKIGRNI

0202

BLKIGRNI WIPER( I WASHER (MODULE

I I

BODY ELECTRONICS (CONTROL MODULE

I I

82640

RED FUSIBLE LINK

DISTRIBUTOR

RED

I -J

HOTINRUN HOTINRUN AND START ___ ANDSTART _r -F ONTPOWER FUSE FUSE DISTRIBUTIONBOX I F45 F28 I 8 A L__I S0/

1 FRONTPOWER I DISTRIBUTION BOX

BATTERY

REDS 5J I <

OFF

START

ACC IGNITION SWITCH

'i~mn"~,

RUN

`11'' J

BRN/BLKT I4T

SRN/BLK(

W/OEGS

GRN/BLK(

W/EGS

BRN/BLK

ELECTRONIC I IMMOLIZER (CONTROL ---- IMODULE(EWSII)

I I

1 BLK/YEL

RED

7 BRN STARTER

-I GENERATOR

BRN( 1 BLK/GRN/

I I 88159

G202

121 X10182

_ J

STARTER IMMOBILIZATION SWITCH

BLK/YEL(

Z-

TRANSMISSION IRANGE SWITCH

I BODY ELECTRONICS (CONTROL - I MODULE

1997-98 318ti

ELECTRICAL WIRING DIAGRAMS

ELE-67

Charging System I1HOTATALLTIMES _ ~_ _1I IGNITION

'1 B . JUNCTION BLOCK

SWITCH

BATTERY

RED

(

I -- - -

STARTER

_ -

I INSTRUMENT CLUSTER

NDRNGNGI

100 03_0 01

3181, 318is, 325 & 3251s

GENERATOR f2 DATA LINK CONNECTOR

88168

HOTATAL TIMES

IGNITION (SWITCH

1994-96 3181, 3181C, 318is, 3251, 3251C, 325is, 3281, 328iC, 3281s & M3

BATTER

STARR

DIODE GENERATOR

(199411995 CANADA)

INTEGRATED CLIMATE REGULATION CONTROLMODULE

ELE-68

ELECTRICAL WIRING DIAGRAMS

Charging System RED

I L

BATTERY

HOT AT ALL TI MES 11 ----- I IGNITION I SWITCH

ISTART START JUNCTION JPOINT

LOCK I

ACC

1TTT

RED

GRN/

- -

BRN

STAR RUN

STARTER

1997-98 3181, 318iC, 318is, 3281, 328iC, 3281s & M3

GENERATOR 88023

RED

FUSIBLE LINK

HOT AT ALL TIMES IGNITION I I 'SWITCH Bf JDISTRIBUTOR STAR T iOFF LL_I 1-1 0

RED

BATTERYJ

I I~

I I I

STARTER

O 2

(7 I

Bj,XlT I INSTRUMENT CLUST I ER CHARGE I WARNINGI IN D I

GENERATOR

DATA LINK CONNECTOR 82641

1995-96 318ti

ELECTRICAL WIRING DIAGRAMS

Charging System HOT AT ALL TIMES

O GENERATOR 122 DATA INK CONNECTOR

88160

TELEPHONE CONNECTOR

ELE-69

ELECTRICAL WIRING DIAGRAMS

ELE-70

Engine Management 19921 .8L (1 of 2)

FRONT_POWERDISTRIBUTIONBO%

UELINJECTION VALVES F4

HOTAT ALLTIMES

M M []M [IM i

AT . LINK CONNECTOR 2oY

_ _ _ __ _ _ _ _ __ _ _ _ FUEL PUMP RELAY

ENGINE CONTROL MODULE RELAY

XZ793

Y I4Y

3Dy BX

eB=85 .1.1 BY

3 L

BRNIWHT 3 32 BRNIYEL INJCTRLI~ L je7 DLCI RED 2S BATTERY 1)27 BFN ECM FLY CTRL SWORN FP FLY CTRL 37 BRNIGRN 02SFLYCTRL GRNIBLU DLCI 80 WHTIVIO DLCI ,88 INJCTRLI

REO

RED

I I' I

I I I

BRN GRN RE O

02 SENS SIB I 7" 7 02SENSGNDI)

2 GROUNDI , 'IB

I I I I I I I I I I I I

IARCVALVEI

BR BRN/BLU

IsCVALVEI} ECM RELAY EEVALVEI~ CVL4IGNCOILI S7~LK 24LBL1( CVL3IGNCOILI ~ BLK CVL2IGN COILI' B2 2

CVLIIGNCOILI

B'=RN

GROUNDI

GF .uNDI ), GROUNOI 3~

BRN

BR" GRN S~

RUNIST ARTI

NCA "= It, INCA

ENGINECONTROL MODULE (DME)

SPIN

HOTATALLTIMES 13B

START

GRN

GRN OF N

~GRN /

GRN

OFF IGNITION SWITCH

BRN

EVAPORATIVE EMISSION VALVE

IDLESPEED CONTROL VALVE

INTAKE AIR RESONANCE CHANGEOVER VALVE

8727 3

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-71

Engine Management 19921 .8L (2 of 2) ER_DIS_TR_IBUTION BOX FRONT _TPOWER

GRN/VIO

FHOTIN I RUNAND START 16

OXYOENSE_NSORRE_LA_Y

I I I

HEATEDOXYGEN SENSOR

CRANKSHAFT POSITION/RPM SENSOR

X,DD> 6

IUE 6A

1185-T86 4Y

13D

18,

INTEGRATED CLIMATE REGULATION CONTROLMODULE

CAMSHAFT POSITION SENSOR I

UV U 2 2 2

~ F

',-

I I

X181.58

X 18185

vvvv - ,T,F E37017

_ _ _ _

I BLK

I I I

GRN

-I

- -I

1 zl zl

. .1

SERVICE REMINDER INDICATOR

BRNIGRN RED/WHT

BLK YEL BLK

BLKIVIO

BRN/ORG

WHT/BLK B LK/WHT

ON-BOARD COMPUTER

r CIOBCOMP 17 T3CIFCINPUT

{IVSOUTPUT IENGINDICAT0R 74 , 1ESINPUT VIOIGRV B6 IICRCMOD Y SLK 1B I CAM SENS SIG EL 44, B I CAM8ETURN yBLK BB CPS SIG EL "' CPS RETURN BLK/ I B PRESSSWITCH I ICYLI-2KS BRN/B (SHIELD-------ORY BLK

BRN/RED GRYIWHTB

ICYL3-4 K5 IECTSENS

59~ITPSINPUT ITPSSENSOR

I,VAFSENSOR _ ( GRY/YEL 41 IVAFSENSOR GRY/SLU 14 ~ INTEMP SENS I GRYRYIV ~INTEMPSENS ENGINECONTROL MODULE (OME) GRYIVIO

GRY/BLU

GRY/WHT

GRYIYEL

GRY/BLK

GRY/WHT SRN

BRN/BLK

VOLUMEAIR FLOW SENSOR

BRN/BL /BL

I IL --!

NORMAL SPEEDRELAY 8727 4

L-

I !

PRESSURE SWITCH

CYL(-2 KNOCK SENSOR

THROTTLE POSITION SENSOR

CYL3-4 KNOCK SENSOR

ENGINECOOLANT TEMPERATURE SENSOR

I I

INSTRUMENT CLUSTER

w-HT/B~~ BLK~VIO l I

2 BLKIWHT " ~~{I VEHICLE SPEED I X17 ( OUTPUT WHT/BLK 21 I FUEL %ifi (CONSUMPTION

GRN/VIO

I I

I GRG~ ~ X1fi I

WlON-BOARD COMPUTER GRNIV10

-i

'EN .IMEBPEE . INPUT

I I I I I I I

ELE-72

ELECTRICAL WIRING DIAGRAMS

Engine Management 1992 2 .5L (1 of 2)

FRONT FO W ER DISTRIBUTION BOX FUEL INJECTION VALVES

871 11

CYL 1-6 FUEL PUMP RELAY

ENGINE CONTROL MODULE RELAY 87AAI

851

30y

86Z~

30 .L

85L . 864,

B71

. J RED/WHT

INJ1~ )3 5 INJ2I NJ 3 IJ4 33 INJ D I~31

RED

BRN/WHT

I I----

I I I~

INJ6I)l~

ECM

CTRL FP RLV Fly OTRL

02SRLV CTRL

BRNIRED BRNIYEL B

_BRNIVIO _BR N

BRN/GRN BRN/GRN

GRN/VIO BRN/GRN RED/WHT

SWITCHED BATT

I I

REO/WHT RED/WI-IT

RED/WHT RED/WHT

W/EGS

RED BATTERVI j26 36 BRN EVAPCTRLI 2 WHT/YEL ISCCTRLI 29 WHTIGRN ISCCTRLI 1 )6 BRN GROUND 1)34 BR GROUND ]) S S B= GROUND B KIVIO CYL61GNCOILI 51 52LKIERN CVL S IGN OOIL

RED

I 1

CYL41GN COILI 50LU BLK/VEL CVL3IGN COILI~24 COIL23~1-KIRED I J' C YL2IGN ~25 BLK/WHT CYLI!ONCO(L, 56 GRN START/RUN T

II I L______ ENGINECONTROL MODULE IOM E)

FI=-----r-_----1------k------f-----

:NEI

HOTATALLTIMES

1 30

START

IL_---_II OFF

IGNITION S WITCH

~2~.2~.

6719 8727 5

CYLINDER 1

;

3121

CYLINDER2

31;.1.21

2l ---j 2_

2131;1

2121;1

CYLINDER3

CYLINDER4

CYLINDERS

IGNITION COILS

-11 G703

3131

IT]

IDLE SPEED CONTROLVALVE

EVPPO M RA7IVE EMISSION VALVE

W/EGS

ELECTRICAL WIRING DIAGRAMS

ELE-73

Engine Management 1992 2 .511- (2 of 2)

FRONT POWER DISTRIBUTION BOX I

OXYGEN SENSOR RELAY

v 30 v87

HEATED OXYGEN SENSOR

CAMSHAFT POSITION SENSOR

CRANKSHAFT POSITION/ RPMSENSOR

INTAKEAIR TEMPERATURE SENSOR

HOTINRUN ANOSTART

ENGINECOOLANT TEMPERATURE SENSOR

THROTTLE POSITION SENSOR

;/~ FRONT F"~ 4/F2SE POWER I F7 (DISTRIBUTION L~- J BOX

W [~~j

INSTRUMENT 23X7 .6 CLUSTER (-__----

1S) X199]9

~// /p~ \\/ f \di/

CHECK ENGINE

O BLK/WHT

BLK/WHT 73 r IVSS GRY 8 ~ ED7a ISRVCREMINO BRN/ ~JECTSENS 3 BRN ~IGROUND BR"/81K 12 ~1TPSINPUT RED/V EL 59~ ISVREF DR IIATSENS YEL 67 ICRNKSHFTSENS BL I CRNKSHFTSENS BRN/ RG 28 ~ I GROUND

GRN/VIO BRNIGRN RED/WHT RED/WH T RED/WHT RED/WHT

-BL YEL

RED RED

ON-BOARD COMPUTER

BLK/VIO

ICAMSHFTSENS 71 , 70 81

ICAMSHFTSENS 0251G

1023 GROUND ION-BCOMP

VIO/GRY 86 ! I A/C L~ IICRCRTLMOD SYSTEM BLK/BLU 48, I IA/C COMP CTRL WHT/BLK 17 BRNIG R LCONS NIG 64JV ~ ITRAN CTRL MOD BRN/ORG 11, I DKV

TRANSMISSIONS SYSTEM

GRV/BLU 88 41 -~ j .AFMETER BLKKIG~y IPRESSSWITCH

HOT IN RUN AND START

I I

(FRONT FUSE pOYfER F28 I DISTRIBUTION -AJBOX

I I

END NE CONTROL MODULE (OME)

6Y X]4017

W/EGS

NOFMALSPEEDRELAY BLKBLK/GRV

z N~I I PRESSURE S W ITCH

GRV/BLU

j 1I 8727 6

-------------AUTOMATIC TRANSMISSION RANGE SWITCH

B 6

GRV/YEL

NOTUSED MASS AIR FLOW SENSOR

20j

1Sj

18~

DATA LINK CONNECTOR

-----------------TRANSMISSION TRANSMISSIONTRANSMISSION CONTROL MODULE (EGS)

GRV/WHT

ELE-74

ELECTRICAL WIRING DIAGRAMS

Engine Management 1993-951 .8L (1 of 2)

FRONTPOWERD_IS_TRI_BU_TIO_NBOX

FUEL INJECTION VALVES

BATTERY

ECM RLYCgXL DI1'27 87 TXDI

FPRLYCTRL I / 023HTRCTRLI 37

ENGINE CO NTROL MODULE RELAY

______

FUEL PUMP RELAY

RED BRN

WHT/VEL

'WHT/VEL WHT/VIO

WHTIVIO

GRN/VIO GRNVIO

BRN/GRN

BRN GRN

ANTII gl BLKIVIO DRIVE AWAYSIG I~~THEFT I SYSTEM VIO/GRV e6 A/CSWITCH I VEL 70 023 SIGNAL I BLK 71 02S SIG GND I BLK/BLU 148 A/C COMP CUT BRN/ORG DKVPOTSIGI // BR/GRV fia IGNTIMING I t BRN/BLK ~66 DRIV E RANGE I I} CVL4IGNCOIL YEL(ORBLK) I 27 CVLSIGNCOILIl62 R~ ED(~RBLKi CYL2101COIL I LK) WI ILK) 25 CVLIIGNCOILI B 66 IGNGROUNDI B, RN~ 6-GROUND BRN SC GROUNDI~

COMPUTER DATA LINES SYSTEM {

WHT/VEL

A/C SYSTEM

BLK/BLU

WHT/VIO

CVL1

DVL2

CVL3

SLKIBLU

CYL4

RED/WHT RED WHT R ED WHT

W/EGS

IGNITION SWITCH

87277

BRNIGRN

-~ A/T RANGE SWITCH

TRANSMISSIONCONTROLMODULE (EGS)

BLK VEL SILK WHTIBLK

ELECTRICAL WIRING DIAGRAMS

ELE-75

Engine Management 1993-951 .8L (2 of 2)

FRONT POWER DISTRIBUTION BOX

- - - -OXYGEN - - -SENSOR - - -RELAY - - - - -I I H OTIN I RUNAND IkjT ;RT~dl

FUSE F18 1sA

I I

HEATEDOXYOEN SENSOR

CRANKSHAFT POSITION/RPM SENSOR

INTEGRATED CLIMATE REGULATION CON7ROLM000LE

CAMSHAFT POSITION SENSOR

87 2Y

GRN

FUEL PUMP zl

¢I

EXCEPT 31811~ "

alGBN/~I

BLK

ENGINESPEED INPUT

WHTIBLK

FUEL (CONSUMPTION

--\

INSTRUMENT CLUSTER SYSTEM 11995, EXCEPT -U)

ANTITHEFT SYSTEM (31811 ONLY)

~ CHECK ENGINE

GRN

GIN/VIO

GRN VIO BRN GRN RED WHT

flED/WHT flED/WHT

BLK 7 ELK

ml 6117

W1EGS

BLK

W/EGS

WH7/BLK

DRY

ELK VEL

WHT/BLK ELK

8, L IENGINDICATOR

ELK

YEL BR N/ORG _____SRN WHT/YEL

ICRANKRPHI ICAMPOSSENS

, ICRANKSENS 67i, ICRANKSENS 28 I SHEILO GROUND 36 ; EEVALVECTRL 2B, I

L ISCVALVECTRL

.I ,ED/W

BRNN/BU BLKIG RR K BRN/BLK

CAM POS SENS

17I FUELCONSSIG

" -f

e5 ( i 15

BATTERY IARCVALVE

AIC PRESS

CYL l-2 KS

4ISENSGROUND

~ICVL3-4KS BRNIFEI 78 IENOCOOLTEMP BR N 12, ;THROTTLE POS GRY/WHT 5 9, I5VSUPPLY GRVIBLK~ I VAF SENSOR GRY/VEL <1, I VAFSENSOR GRY RY/BI VAFSENSOR GRV/VID 77 { , VAFSENSOR ENG ME CONTROL MODULE (OME) GRY IVIO

GRV/BLU

GRY/WHT

GRYIYEL

GRYISL VOLUMEAIR FLOW SENSOR m

199531811 819930NLY

GRYIWHT ~~BRNIBL gRNIBL

1 J.

1 .l

2A,

EL VAPORATIVE IDLESPEED EMISSION CONTROL VALVE VALVE 8727 8

INTAKEAIR RESONANCE CHANGEOVER VALVE

I I L__i

NORMAL SPE EDR 1 BlI (1 9953 811 81 9930NLY)

PRESSURE SWITCH

LT CVLl-2 KNOCK SENSOR

t 2 3 THROTTLE POSITION SENSOR

2,J

BRN BRNIBLK

CYL3-4 KNOCK SENSOR

ENGINECOOLANT TEMPERATURE SENSOR

I I

ELE-76

ELECTRICAL WIRING DIAGRAMS

Engine Management 1993-95 2.51 (1 of 2) FRONT PO WER DISTRIBUTION BO% FUEL INJECTION VALVES SOLENOIO VALVE (RUNNING LOSSES) (1995 ONLY)

CYLl

CVL2

CVL3

CYL4

BEN

? 1995 ONLY

WHT BLU

BRN

SOLID STATE

CVLS

RED/

WXTBLU 1717

CYL5

CYL 1-fi FUEL PUMP RELAY

ENGINE CONTROL MODULE RELAY

STARTING SYSTEM

Bt LKIVEL

GRN

50 55 30-7 RED

GRNIVIO BPN/GRN BATTERY CYL21NJI~ BRN/VEL 31 CVL3INJ1 ~ CYL41NJI77

I I I

PED

1995 _~ 7NLV

/BLU

RED RED

BATTERY(

CYLSINJI

PN /GRN CYL5INi ) j~ -BB

THROTTLE FLAP

I 1)12

I-

~I RED I ( I I

1995

RED

E%CEPT 1995

RED

Bt JUNCTION POINT

WIEGS

REDIWHT

RED/WHT

SPLICE ---------------RED/WHT

RED/WHT WHTIGRY WHT/GRN

IGN CUT-OFF I )B3 52 H /RED/VEL EMLSIGNAL ) W~ NIBLU CAM ACT CTRL ) ~36RN EEVALVECTRLI 12)--_ WH=IYEL ISCTFLVALVE I~29 WHTIGRN ISCTRL VALVE I , 15ILI GROUND NCA 1 4 5 I ~~ SHEILDGND B RRN INJGROUND 15~-GROUNDI j34 BIN 55 BEN IGNGROUND) 24LK/V10 CVLSIGNCOIL)I BLK/GRN CVLSIGNCOILI j25 23 BLK/8LU CVL4IGNCO IL II52BLKIYEL CYL 31GN COIL I 51LKIRED. CYL21GNCOILI 9LS/WN7 CYLIIGNCOILI 50_ IGNSWITCH 1)56

WHT/ GRY/YEL

ENGINECONTROL MODULE(DME) 1995 ONLY r~I ~~

HOTATALLTIMES I30

START

RU N

)

OFF

I 1 GRN ~ "

GRN

-I

IGNITION SWITCH

~: j

1 87279

3J,1,k2,1

6-1--l 3 2

--IJJ 3 2

--ljJ 3 2

tlJil 3 2

Lull CVL1

Mll CVL2

Lull CYL3

FRII CYL4

Immil CYL5

CVLfi

IGNITION COILS

T-

-4J

6119

IDLE SPEED CONTROLVALVE

EVAPORATIVE EMISSION VALVE

2J-L

( CAMSHAFT ' ACTUATOR

5,1,

b,l

~: j 25

2fi,J.

I ________SLIP CONTOL MODULE (PBS/AS C)

ELECTRICAL WIRING DIAGRAMS

ELE-77

Engine Management 1993-95 2 .5L (2 of 2)

FRONT POWER DISTRIBUTION BOX OXYGENSENSORRELAY

HEATEDOXVGEN SENSOR -

CYL1-3 KNOCK SENSOR

CRANKSHAFT POSITION( RPM SENSOR

CYL4-6 KNOCK SENSOR

INTAKE AIR TEMPERATURE SENSOR

THROTTLE POSITION SENSOR

nFffi

HGTIN RUN IA ,FROOWNER T EP I PD (DISTRIBUTION TEA' L-J B0%

ENGINE COOLANT TEMPERATURE SENSOR

141

X 1001

I I I I

INSTRUMENT CLUSTER

CHECK ENGINE

I I

I I I I

VEHICLE I SPEED I OUTPUT 18t'xt6

2Yx1Z.

BLK/WHT

G312

GRN/VI O

GRV

bz ~IVSPEEDSIG

~'CHECK ENGIND 78 ENGCOOLTEMP BRN 44, SENS GROUND BRN/BLK ~ I -< TPOSSENS REDIYEL 68 ' I 77LI6VSUPPLV G RV INTK AIR TEMP =LK 7~ I CYL4 -6KS ~BRN/ORG 71 I 7 o IKSGROUND BRN/RED

BRN/GRN RED RED

W/O EGS

SPLI_E - RED/WHT

RED/WHT

/I\

RED/WHT W/EGS

W/ E . .

INSTRUMENT CLUSTER

WHT/BLK ELK

ANTI-THEFT PRESSURESWI7CH BLKK/B~SVBITEM

~~~CVL1-3KS j VEL18 ~CRNKSHFTPOS BLK 43, ICRNKSHFTPOB BRNIORG 26 ISHEILDGROUND BLK 40 I02SSIGGND VEL 13, 102S SIGNAL GRN ORBLKlV10 66 I DRIVE-AWAY SIG BLK/GRY 65 A/C PRESS SIG VIOIGRY B WHT/BLK

BRNIORG BRN/GRV

BLK WHT/VIO

COMPI U^

WHT/VEL

WT/VIO H vc

WHT/VEL

I IAICSWITCH AIC COMP CTRL I IFUELCONS

I7 VALVEPOS IGN TIMING 47 I 88ICRNKSHFTRPM ITXDDATA 87 IR%D DATA I

HALL EFFECT CAMSNAFTSENSOR

! ______ ___-----------TRANSMISSION_ CONTROL AUTOMATICTRANSMISSION G117 MODULE (EGS) RANGESWITCH 87200

I I I

I I I I I I I

ELECTRICAL WIRING DIAGRAMS

ELE-78

Engine Management 1996-971 .9L: (1 of 2)

UEL INJECTION VALVES CYL4

I I I I I I I

rcl

CYL2

CYL3

rENGINECONTROLMODULERELAV

I 1-=JI

FUELPUMPRELAY

W/_ 213 i/3 il

I L

CYLI

FRONT POWER DISTRIBUTION BOX

HOTINACC,RUN ANDS=ART ,FRONT _ USE POWER F46 DISTRIBUTION BDX X10016

ACTIVATEVALVE I 31 BR~NIVEI ACTIVATEVALVE BRN/WHT ACTIVATEVALVEI 32 BRN/YEL ACTIVATEVALVEI 3 2S RED BATTERYVOLTI 57 RED/WHT NORMAL ACTIVATERELA SPEEDRELAY 27 BRN/WHT ECMRLYCVO L 1)54 RED/WHT B AT7ERV LTRT 63 BRNIGRN ACTIVATERELAVI~--~YJ~ TXDI 88 HT/VIO H=~ /YEL RXD 1 8~7~ W 1.t~p B~/VIO LK ANTI-THEFT DRIVEAWAYSIGI BLK SYSTEM 808p CRANKSHFTRPMI WHT/GRN PROGRAM VOLTI 60 BLK/ ACTIVATEA/CI 1I BLK BLU 66 GRY/)---~~SYGITEM TEMP SIGNAL) 89 VIO/GRY SIGNALA/C ON 36 BLK/ AICCOMPCUTI 86 YEL CAN HIGH

I I

WIEGS

BLK/BLU

e~-

CAN LOWI 179 BRNIRED RR SPEEDSIGI B~U 23~ CY14IGN COIL

I E I I

CYL3IGNCOILI 5 o R D CYL2IGN COIL 49 CYL 11GN COIL 5= IGNGROUNDI INJGROUND

1997, W/ABS

AL-'GRN

OROUNDI IGNSWITCH

W/ASC, EXCEPT 199831871

ENGINECONTROL MODULE(DME) HOTATALLTIMES

BRN STRT~~l GRN_

I I I

RuN~_J

" 161 ACC I OFF

G117

IGNITION SW ITCH 7997 86

_--- -- .-----

GRN

BR N

7996 GRN

G777

f-W/EGS

I ABSCONTROL MODULE/ HYDRAULIC UNIT

1996

BRN

851

DR. /

GRN

Z GTN

31811 (RD

UNLOADERRELAY TERMINAL15 (19970NLY)

EXCEPT 31871

EXCEPT 1998 31811

I RED

B,JUMPSTART JUNCTION POINT (EXCEPT318U)

mlulm 1 1GNI OIL$ C S

6119

1,1,3A,2,1,

II CYL1

2,J,3,4

II CYL2

2J,3,IJ f,

2,1,3,1 L,

II CYL3

II CYL4

=,1=7,,

lS J,

I______I SLIFCONTROL MODULE (ABSIASC)

65,1,=8,1, 48,1, 60,L, 40,1, 87,E 88}, 54}, 55A, 28},

I_______________ TRANSMISSION CONTROL MODULE (EGS)

88547

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-79

Engine Management 1996-971 .91-(2 of 2)

HOT IN RUN AND START

I I I is Y

FS iDA (199fi)

-1FRONT (POWER FUSE IDIS7RIBUTION F (BOX ISA (1997)

HOT FILM AIR MASSMETER

HALLEFFECT CAMSHAFTSENSOR 1

CRANKSHAFT POSITION/RPM SENSOR

ELCTRONIC IMMOBILIZERCONTROL MODULE (EWS11)

iBy $1D01B

IENGINESPEED

- k I INPUT BLK

GRG=1fi~ WHT/BLK

INSTRUMENT CLUSTER SYSTEM

I I FUEL I CONSUMPTION TEMP SENS (L)

~GRN/RED 133 SRN/VIjg BRN/V=L

FUEL

17{iTEMPSENS(-) INSTRUMENT CLUSTER

EXCEPT 1997 318ti

GRN/VIO BLK

CHECK ENGINE

21 I X t fi'C CONSUMPTION

FUEL PUMP

SPLICE

----- .--_ .------ENGINECOOLANT TEMPERATURESENSOR

EXCEPT 31811

WW=TIBLK

BOR4

__J

ON-BOARD COMPUTER

_ ---- I BRN/RED 74, r ~ITEMPSIGNAL I ~GRN/RED 42J ~IFUELCONSUMPT I WHT/BLK 83 I VEHICLE SPEED I GRV S, IENGINDICATOR I VEL 78 -

-~{ICRNKPOS/RPM _ILL -(ICRNKPOSIRPM BRN (SHIELD GROUND I21 YEL CAMSHFTPOS GRV/BLU 17 'GROUND 4S GRV/V10 :SIGNAL VEL 77, SENSOR SIG 8-{ I02. .SORGND :. BOISHTNG GND VEL 19 3D~I023ENSORBIG B 02SHTNGGND BRN/VIO B7 ACTIVATEVALVE ~BRNIG RN29 I ISC VALVE CTRL 2 BRN VALVE BRNIBLU~JACTIVATE BIACTIVATEVALVE BILK 70 ~ ;CVL 1-2KS BLK -~{ CYL 3-6 KS BRN/BLK 711 ~ SENSGROUND BRN/RED IINTKAIRTEMP BRN/VIO 44 THROTTLEPOS

- W I SVSUPPLY GRVRY/

I - ~ J{ I -' 40 I

L~~~ I

~ W

ENGINECONTROL MODULE (DME)

THROTTLE POSITION SENSOR

88648

OXYGENSENSOR (BEHIND CATALYTIC CONVERTER)

OXYGENSENSOR (FRONT OFCATALYTIC CONVERTER)

EVAPORATIVE EMISSION VALVE

IDLESPEED CONTROL VALVE

INTAKEAIR RESONANCE CHANGEOVER VALVE

I CYL1-2

CYL3-4

KNOCKSENSOR

INTAKEAIR TEMPERATURE SENSOR

ELECTRICAL WIRING DIAGRAMS

ELE-80

Engine Management 1996-97 2.8L (1 of 2) _

FRONT POWER DISTRIBUTION BOX _ _ _ _ LMODU_LERELAV FUELINJECTIONVALVES 'EN GINECONTRO VARIABLE CAMSHAFT CONTROL VALVE 1

_ __ _ _ _

CY L_1-E_FU_EL_PU_MP_RELAY HOTINRUN ANDSTART

UNLOADER RELAY TERMINAL IS (1997 ONLY)

ILU 21GR BRN1WHT CYL11NJI 1T 5 BN1RED CYL21NJI ) 69 BL NIGRN ACTIVATE RLYI ~ 122B YY=L CYL3INJ 12424 BAN/B-U :INJ CVL CYLSINJ I 33 BBRNIGRN B 10 CVL6INJ 123 773BRN ACTIVATE FLY I BATTERYI 2~ ~ jiB GRN DRIVE -AWAYSIGI REDIWHT BATTERYI 87 BATTERYI 54 REDIWHT BLK/GRY ACTIVATEAICI 16 WHT/GRY/YEL THROTTLEPOSI 45 WHT/GRY ASC-SIGZWVIi81 80 WHT/GRN ASC-SIGZAI )82 WHT/RED/YEL ASC-SIG MSRI L IS B NIRF=D SPEEDSIGRRI SPIN CYL 4-6 KS 163~ 59 G RN CYL4-6KSI 58 BLKK CYL1-3KSI I YEL CYL1-3KSI 57 38 N .A GROUND ~--~ ~BRN ACTIVATE RLYI 68 ILT/YEL ACTIVATE VALVE 27 WL TIGRN ACTIVATEVALVE 4 GROUND I / BRN GROUNCI )34 8 GROUND I 32 K/V10 L I 3 CYLBIGNCOILI 31~S CYL 51GN COIL I B L=/BLU 2 CYL41GNCOILI )30 BLK/YEL CYL31GN COILI CAMSHAFTCTRLI

1 G312 R=D RED

* ANTI-THEFT SYSTEM

EXCEPT 1996M3

REDIWHT RED/WHT

PRESSURESWITCH

j )"

HOTATALLTIMES

I I

I 1 GRN

START RUN

I I

OFF _I ACC _

IGNITION SWITCH

3,aj

MiiFRii [711 CYL1

88893

CYL2

CYL3

3j,1

ii Tii Mii

CYL4

GNIT10N COILS

CYLS

CYL6

1)a),2,

MILE SPEED CONTROL VALVE

ail

EVAPORATIVE EMISSION VALVE

zl zl zl zl il z

CYL1-3

CYL4-8

KNOCKSENSOR

33.I

I I

33~

________SLIPCONTROL MODULE (ABS/ASC)

ELECTRICAL WIRING DIAGRAMS

ELE-81

Engine Management 1996-97 2.81L (2 of 2)

SECONDAIR PUMP RELAY

ID SO VALVE (RUNNING LOSSES)

SECOND AIRPUMP VALVE

CARBON CANISTER VALVE

EXHAUST UST FLAP VALVE

OXYGEN SENSOR (INFRONTOF CONVERTER)

OXYGEN SENSOR] (IN FRONTOF CONVERTER)

````

OXYGEN SENSOR (BEHIND CONVERTER)

OXYGEN SENSOR] (BEHIND CONVERTER)

CAMSHAFT POSITION SENSOR (CYLINDER ID)

aa a

. .U

INTAKE AIR TEMPERATURE SENSOR

~t 11~

DUALTEMPERATURE SENSOR (COOLANT TEMPERATURE)

f 2f ~ 1 ~ O RN/RENN~ I X17 I . WHT/BLK 21 I

I I I I I -GRrr,~I I XL6 I-_-J BRN/VIO

~BRN/YE~L~17_~

INSTRUMENT CLUSTER

I I

IGRY

GRN/RED SRWRED

20-

GRY NCA

BLK VEL

BR N YE

I FUELCONS

GRV/BRN

ICHECKENGINO IFUELCONS

I ENGCOOLTEMP

(GROUND IINTKAIRTEMP

(GROUND 64, (GROUND 65 ICAMS HAFTPOS 43 ~ICAMSHAFTPOS S, ISENSO RSIGNAL

I 1 I I I I I I I I I

, I02S SIG GNO

I02SHTGGND

YEL ~ISENSORSIGNAL BLK 71 1 025 SIG GNO B SRN

BLK

70,

I I 02551GGND

1 02SHTGGND 02S H TG GND

255,SENSORSIGNAL BRN B~1025HTGGND Y~102SSIGGND

AI C SYSTEM

EXCEPT1996M3

-~ SENSORSIGNAL GflV/V=0 BIGEXHSTFLAP GRN/BLU 61, IACTIVATEVALVE BRN/WHT 62 IACTIVATEVALVE VEL/BLU 50 IRUNNINGLOSS BRN/GRN 35 IACTIVATEVALVE BLK 85 ICANLOW VEL 86 CANHIGH BLK/BLU 74 -~IACTVA/C COMP VIO/GRY 19 A/C ON BIG BLK 36 I CRNKSHFTRPM GRN/BLU 60, I PROGRAMVOLT WHT/VIO/VEL 88 TxD 6 YEL HOTFAM MTR SILK 7~ HOTFAMMTR BRN/0= 1 (GROUND YEL 4 < IVOLTSUPPLY .LK 'ISENSORSIGNAL .BRN/B=400 (1 GROUND VEL/RED 11

I I

I I 1 I I I I I I I

IFUELTNKPRES REDIGRN 00 ~IVOLTSUPPLV BLK 12ITHROTPOSSIG BRN 42 GROUND

COMPUTER DATA LINES (1997 0 N LY)

ENGINECONTROL MODULE (DME)

NCA (1997 ONLY)

J] 0 1 -k 1

RE /GRN 3, I ~ THROTTLE POSITION SENSOR

1 L,2)13)l

¢I

14,L, 2s,t, 54,1, 95,1, as,t, 60,1, 99,L -

I I

i -----------~ TRANSMISSION CONTROL MODULE(EGS) 68894

18~

17~

¢I

19~ .~

ml _

R MASS METER

~6117

YEL/RED

BRN/BLK

2 FUELTANK PRESSURESENSOR

ml ml

DATA LINK CONNECTOR

MASSMETE

GRV/WHT

CRANKSHAFT POSITION/ RPM SENSOR

ELE-82

ELECTRICAL WIRING DIAGRAMS

Engine Management 19981 .9L (1 of 2)

FUELINJECTIONVALVES CVL4

I I

CVL3

HALLEFFECT CAMSHAFT SENSOR

HOTFILMAIR MASSMETER

CYLl

CVL2

FRONT POWER DISTBIU710NBOX

______. ___

BRNIWHT AC7IVATEVALVEII BRN/V EL ACTIVATE VALVE I'3 1T SIGNPLINPUTI AN B 2 ACTIVATE VALVE I-4B6~GRV/VIO GROUND ENGINO1CATOR DRIVE AWAY SIG

I I~ I I 10

BLK/VIO

BLKIGRY TIVATEAIC 31 BRNIBLU ACTIVATE AC VALVEI 32~BRTI/GRN ACTIVATE VALVE 120 BLK CRANKPOSIRPMI YCAMSHAFTPOSI 21 11

I I

BATTERYVOLTI126 1 )21 ECM RLV CTRL 18 INTKAIRTEMPI

CVL3-4KSII FU ELCONSUMPTI

40 42

RED 8RN/WHT BRNIRED

6 GRNIRED

B RN/VIO

136 A/CCOMPCUT I

8LK/BLU

THROTTLE POST

I I I

"HIRED

8LK/BLU " -

SYSTEM 53 2

5VSUPPLVI ISCVALVE CTRLI

30 BRN 02SENSH7NGI~19 VEL 02SENSORSIGI~ 1 BRN 02 SENS HTNG 4 SENSORGRNOI 23 BLU CVL4IGNCOIL ILI 2rCVL3 ON INJGROUND I BRN GROUND 128

/GRN

GROUNDI)~pl 54

BA7TERVVOLTI IGNGROUNDI CYL21GN COIL CYL1IGNCOIL IGNSWITCH ACTIVATE FAN ACTIVATE VALVE

RED/W~

t f

READ ED

I ~~ II I l

50 49 56 B7

WHT GR " GRN

NORMAL SPEED RELAY

REOIWHT

L_____!

ENG ME CONTROL MODULE (DME)

I I

HOTPTALLTIMES ___

START

GRN

RUN ~_I 18 ~ ACC I OFF

GA .

IGNITION SWITCH 4

a IGNITION COILS

108624

mIm

3~2

OXVGENSENSOR

IDLESPEED CONTROL VALVE

EVAPORATIVE EMISSION VALVE

INTAKEAIR RESONANCE CHANGEOVER VALVE

ELECTRICAL WIRING DIAGRAMS

ELE-83

Engine Management 19981 .9L (2 of 2)

r_-_---_________________________-_--I ^

(

FUSE

(

I L-______1L_1 15 A

m U SE

`~6A

16Y- 167xloo16

34Y

FRONT POWER (DISTRIBUTION I Box

SECONDASECONDARY

I I ______J

CRANKSHAFT POSITION(

CRUISE CONTROL MODULE _RPMSENO

I I I --I

RELAY

ELECTRONIC IMM OBILIZE R OONTROLMODULE

I I I __I

12Y

2 POWER DISTRIBUTION

FUEL PUMP

AIR PUMP

CARBON CANISTER VALVE " BR~L I-

OATALINKCONNECTOR 14T

18T

1 T 15T

m l

BLK GRV

20 16

I-----

s 2

RED

CRY

G103

ELK BRN/GRN

4 6

a ENGINECOOLANT TEMPERATURESENSOR GRNIRED 10 11 12

WHT/GRN

BRN/VIO

BRN/VIN 61 ~(ACTIVATEVALVE BRN/GR N 63 ACT IVATEREL AY GRNIBL ACTIVATE VALVE

GRY/WHT

SPLICE---__~--`------

FUEL CHANGEOVER VALVE

VALVE

BRN/WHT

GRV/VIO VIOIGRY BRN/BLK B INIIHT YEL/RED

YEL

YEL BRN/CEO BLK

BLK

YEL/RED BLK VEL

" (~

PROGRAM VOLT

¢ a

86,4,

8554,4. 55 ,1~ 46J, 26,E 60J, 40B-

I II I I I I_____-I I_-_________-___SLIPCONTROL MODULE (ABS/ASC)

72 70 B6

WHT/BLK B3

COMPUTER DATA LINES

7J,

TEMP SIGNAL

I I

(FUELTNKPRES ICYL1-2KS I CANLOW (

ICAF .D-G (TED VEHICLE SPEED ENGINECONTROL MODULE (ODE)

6J,

IA/051GNALON 71 ~ I (SENSGROUND ACTIVATE RELAY 66 (ACTIVATE VALVE 77 I02SENSORSIG 78 i JCRNKPOS/RPM 7S IRRSPEEDSIG 80 CRNK RPM S PD

WHT/VEL B7 WHT/VIO 86

W/ASC

33J,

BLK BS

YEL

ABSCONTROL MODULE/ HYDRAULIC UNIT

ITEMPSIGNAL

YEL/RED

W/PBS

SECONDARY

II AIRPNMP

A/C SYSTEM

10862 6

---

BR"/ED

YEL BLK/BLU

BRN/VIO

TRANSMISSION CONTROL MODULE (EGS)

88,+,

I I I

zl z~

CYL1-2

il z CVL3-4

KNOCKSENSOR

ELE-84

ELECTRICAL WIRING DIAGRAMS

Engine Management

1998 2.5L (3231), 2.8L (3281), 3 .2L (M3) (1 of 2) FRO_NT_POWWE_RD_IST_RI_BU_TIO_NB_0%_________________ rENGINE CONTROL MODULE RELAY CVL1-6 FUEL PUMP RELAY

FUEL INJECTION VALVES

VARIABLECAMSHAFT CONTROLVALVE1

UNLOADERRELAY TERMINAL15

GRNIBLU CAMSHAFTCTRL'f21 L 6 B N/WHT CYLIINJI 5 BAN/RED CYL21NJ) BLK/VIO/VIO CYL61GNCOILI 1 3 B7 GROUND L7 YEL HOTFAMMTRIj3 ] 10 BRN/RED ENGCOOLTEMPI PK WHTIBL FUELCONSI 12 THRO7 POS SIG I 2 BK/BLU CYL41GNCOILI 11 RED FUELTNKPRESSI 14 GRV INTKAIRTEMPI SRN/RED 15 SPEED SIGRRI 16 BLK/GRV ACTIVATEpiC I 18 GRN DRIVE-AWAY SIG

A/C ON SIG CHEKCENGIND) CYL 21GNCOIL)

)1D 20

VIO/GRY

l 22

BLKIREO

I 1 1 1 1I ,K I I II

REO

BRN/YEL BRN/BLU BRN/VIO

GROUND

BRN/GRN

SPIN

BRN/RED

REO

02HTGGRNOI 25 SPIN 26 RED I BATTERY] 14 I pCTIVAT I 27 WH7/GRN o28 BRN/ORG I CYLIIGN COIL]

A/C SYSTEM

ANTITHEFT SYSTEM

GRY

CVL3INJ I 20 SVL4INJ CVL6INJI123

WHT//YELL RED

RED

RED BRN/GRN

RED/WHT RED /WHT

REDIWHT

RED/WHT

REDO

RED/WH7

RE //WHWH TT

REDIWHT

RED/WHT RED/WHT

BRN NCA BRN RIDIWHT

RED/WHT NCA

BLK/WHT

BLKIVEL CYL31GN COIL] 30 BR` N GROUND] 34 BRN BR~ N~ 32 I GROUND I BRN/GRN I CYL51NJI 33 BRN . I GROUND) 44 35 BRN/GRN ] I ACTIVATERELAY 136 BLK I CRNKSHFTRPM 31 BLKIGRN I CYLIIGN COIL] G ROUND 138 NCA I GROUND] 39 DRY/SRN 40 BRN/BLK GROUND I NCA I GROUND] 41 42 BRN I GRE OUNOI 43 BRN CAMSHAFTPOSI RED/GRN VOLTSUPPLYI 44 WHT/GRY/YEL ] THROTTLEPOSI 45 46 GRN/RED I FUELCONSI I 46 YEL

WHT/YEL WHT] GRV/YEL

BRN/ORG BRN

BRN BLK YEL

]

BLK

RED/WHT

2 3 4 5

7 6 G

10 1 1

15 16

17 18 1. 2,1 21

1'E BRN/ORG

1 HOTFILMAIR MASS METER

~r ___I G

WHT/6LK

21~I

I I

MODULE (DME) GRN/RED

HOTAT ALLTIMES

BRN/YEL

17, ;7 %

I I I I L__J

INSTRUMENT

31 4:1 BI

T ..G125 1. 106626

171,

CVL1

71 , 17 ,171, 711 [Tilu CYL2

CYL3

CYL4

IGNITION COILS

CVLS

CYL6

>I .1 .1

IV] 1-1 IDLESPEED CONTROL VALVE

FUELTANK PRESSURE SENSOR

GRV/BRN

3 1211 I 1~

THROTTLE POSITION SENSOR

IHTAKEAIR TEMPERATURE SENSOR

-1

DUALTEMPERA7URE SENSOR (C00 TEMPERATURE) TEMPERAT RE)

ELECTRICAL WIRING DIAGRAMS

ELE-85

Engine Management

1998 2 .5L (3231), 2.8L (3281), 3.2L (M3) (2 of 2) FRONTPOWERD/STRIBUTIONBOX

1 I

SECOND AIR PUMPRELAV t -~

EVAPORATIVE EMISSION VA VALVE

CAMSHAFT pOSITIONSEN50R CYLINDER ID)

SECOND AIRPVMP VALVE

SOLENOIDVALVE (RUNNING LOSSES)

CARBON CANISTER VALVE

KNOCKSENSOR

EXHAUST GASFLAP VALVE

CYLd-fi

CVL 1-3

2I 2I 2I ZI ZI Z

2 t

1 3 4 6 B

WHT/GRV/VEL RED .ED

RED)-

I I

BRN/GRN

BRN BILK VEL

.RN

ILK BRN

RED/WHT PED/WHT

BRN/GRN

BRN N CA

(ACTIVATE VALVE I SIG EXH5T FLAP ( BATTERY

BRN

RED/WHT 'NCA

WHT/YEL

W-1 GRY/YEL

328 AND M3 ONLY ON

WHT/GRV

VEL

BLK

WHTIRED/VEL

BLK

YEL

86 87

BLK

HIE 44 1

H-

SIG GND 701 `1025 1025SIGGNO 61` 02SHTGGND 73~ IACTIVATERELAY 72, 75'102SSIGGNO

BILK INSTRUMENT CLUSTERSVSTEM

I I I I I I

_IACTIVATEVALVE 63, 1ICVLd-fiKS 64 (GROUND 66 ICAMSHAFTPOS B6 I 025HTGGND I fi7 102SSIGGND fib I ACTIVATEVALVE I 69 ACTIVATE RELAY

I I BLK I YEL ' ISENSORSIGNAL I ISENSORSIGNAL I YEL 77 ` ISENSORSIGNAL I YEL 78 ISENSORSIGNAL I I I WHT/GRN BD I IASC-SIGZA 6LK

BRN

BF.

BRN

.HT RED/

RED/WHT

BRN/GRN

RED/WHT B

WHT/VEL

Gt03

GRN/BLU GRVIVIO

F -#- I

REDIWHT

102SHTGGND

I I1

A50-SIG ZWV ISENSORSIGNAL

I ASC-SIGMCR I

CAN LOW I (CAN HIGH (BATTERY

WHT/VIO/VEL

END NECONTROL MODULE (ONE)

WHT/REDIYEL

WHT/GRY

WHT/GRN

4 15

I I

WHT/GRV/VEL WHT/GRY/VEL

I I SLIP CONTROL MODULE (ABS/A SC)

G103

6 21 84,L~ I I

28,E

B - 88,1,

80,1

88,E

171

DATA LINK CONNECTOR

--TRANSMISSION CONTROL MODULE (EGS) 1SB627

CRANKSHAFT POSITION/ RPMSENSOR

OXYGEN SENSOR(

OXYGEN SENSORII (-AN-)

OXYGEN SENSOR I

OXYGEN BENSORII (328ANOM3)

ELECTRICAL WIRING DIAGRAMS

ELE-86

Data Link Connector 1992-93

r I

HOTATALLTIMES

DATA LINK CONNECTOR

IGNITION I SWITCH

I I

START

LOCK

STARTER 1 RELAY I

ACC RUN I 1 L______ v J

HOTATALLTIMES r - -I B . I I JUNCTION L J POINT

HOTIN STARTANDRUN FUSE R2B 15A(1992) 1 .,A(1993)

-1PRONTPOWER (DISTRIBUTION BOX I,

W/OEGS

W/E GS

STARTER

OTHERS _ _

1093 326

7~ 47 BLK

1 1

888

WHTIVIO

h 87 . WHTIYEL

WHTIVIO

5{I

WHTIYEL

ON-BOARD COMPUTER

ENGINECONTROL MODULE (OME)

I "

B~K

1992

WH=O WHT/V~L 1 I I I

I I

GRN/BLU

WHT/YEL

BLK

1 I 13 WHT/VIO I 1` L_ _I TRANSMISSIONOONTROL MODULE (EGS) I

-I

BLU 6 I WHT~I 20

12 ,

I 11 , I L__I INSTRUMENT CLUSTER

1992 .1993325

WHTIYEL

23 ,I

BLU BK

161

WHTIV=O

16~,

I 1

__ SLIP CONTROL MODULE(ABS)

WHTIYEL

3 B

7I~OTHERS

9 ~ LATE PRODUCTION 1993

SRSCONTROL MODULE (1993 LATE PRODUCTION)

INTEGRATEDCLIMATE REGULAT ON CONTROL MODULE

WHT HT/

WHT/I WHT

I CENTRALLOCKINGMODULE

(OTHERS) 641102

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-87

Data Link Connector

1994-95 Early Production Except 318ti r

HOTATALLTIMES _

1IGNITION

I (

I I

( SWITCH --- I START

LOCK

IACC

RUN

STARTER RELAY

I I

yt~p

_ 3

'if y ff

DATA LINK CONETR_

HOTIN HOTATALLTIMES

_ 7-

r _l B+JUNCTION

aItYY71' ~ 8 910tJ1~=1131G I I

2of

STARTANDRUN

( POINT

_j POI (EXNT)

L I

B+JUMPSTART JUNCTION POINT

FRONT POWER 1 FUE1 S , DISTRIBUTION BOX / FUB I

,_`1y'I

1O=J

(M3) 1

I FUELP I

STARTUMR/

I IDENTIFICATION

RELAY

IOEGS

WIEGS

BLK/VEL

GENERATOR

STARTER

UNCOUPLING

3181

BLK

WHTIVID

I I

DIODE (M3)

I, }WHT/VEi B7 __

ENGINECONTROL

WHTIVIO

WHTIYEL

I I

MODULE(OME) ON-BOARD COMPUTER

WHT/VIO I

WHTIYEL 3

VARIABLE CAMSHAFT

WHT/VIO

CONTROLMODULE(VANOS)

WHT/YEL

BLU

WHT/GRNN

I I

'Lo

B WHTIVIO

WHTHTIY

WHTIVIO

I ~, 25

wYEL

BLK

I I

EX M3

L ._I

WHT/VIO

INSTRUMENT CLUSTER

EXM3

TRANSMISSION CONTROL MODULE (EGS)

1 I

w T/VIO

WHT/VEL

1995

WHTIVIO

BODYELECTRONICS

WHT IVIO

WHT/VIO

CONTROLMODULE (ZKEIV)

SLIP CONTROL No DU LE (ABS)

-D

BSI 3

WHT/VIO is

CRUISECONTROL MODULE (1995) 83372

wHT/Y

I-___I

!_ I

CONVERTIBLE TOP

SRSCONTROL

CONTROLMODULE

MODULE

I I

INTEGRATED CLIMATE REGULATION CONTROLMODULE

ELE-88

ELECTRICAL WIRING DIAGRAMS

Data Link Connector

1995 Late Production Except 318ti

r 1

DATA LINK CONNECTOR

B 1D 11

12 13 I A 16 16 17 18 19 20

HOT AT ALLTIMES r 1 BI JUNCTION I I POINT J(EXM3J L B,JUMPSTART JUNCTION POINT (M3)

HOT IN STARTANDRUN SE,FRONT POWER r FU DISTRIBUTION BOX F26

I L

`( 12 (

D-

I J

-- I

GENERATOR

3181 3261

r ~ 77 47 I' 68~

I I

88~ v 87

BL I T/VIO

WHT/VEL

ENGINECONTROL MODULE (DME)

WHT/YEL

WHTIVIO

I I --I

ON-BOARD COMPUTER

I S 11

WHT/YEL

S B I -k, B

HT/GRN

WHTT/GI VARIABLE CAMSHAFT CONTROL MODULE (VANOS)

h I' I I I, --I -

WHT/V 0

12 ~

WHT/YEL

WHT/VIO 26i 11

---I I I

,I L__I

INSTRUMENT CLUSTER

BLK

TRANSMISSIONCONTROL MODULE (EGS)

WHT/VIO

2 ,i

-I

_ -I

ELECTRONIC IMMOBILIZER CONTROLMODULE(EWSIN

___

j, 11 I' B

WHT/VIO WHTIYEL

__l BODYELECTRONICS CONTROL MODULE (ZKEIV)

WHTlv_

WHT/VEL

SLIP CONTROL MODULE(ABS) o BLK WHTrv

I WW HTrvW="

__I

CRUISECONTROL MODULE 88960

__I

CONVERTIBLECONTROLMODULE

I _I

SRSCONTROL MODULE

I _I

PARKDISTANCE CON TROLMODULE

I I

NTEGRATED CLIMATE REGULATIONCONTROL MODULE

ELECTRICAL WIRING DIAGRAMS

ELE-89

Data Link Connector 1996-97 Except 318ti

HOT IN START AND RUN

HOTINACCV, START AND RUN

BE F26

FUSE, FRONTPOWER (DISTRIBUTION BOX F46

- _____

I Li t A

DATA LINK CONNECTOR

5=J

7( 8

HOTATALLTIMES 1 B, JUNCTION

`(`(

8 10 11 12)13 14/75Y fiI17I18I12201

1 .1

J (9 8(5) B,JUM

START POIN

(M3 .3P81)

VIO/YEL

0BOII CONNECTOR

BLK/VIO/YEL

WHT/VIO/YE

328 1, M 3

OTHERS

31818 3281, M3

--__l

I I I-__I

8~6D

III BB88 I 88 I 87

WHTIGRN WHT/VIO/YEL

1997

WHTIVIO " -T/ WHT/YEL

ENGINECONTROL MODULE (CME)

WHT/YEL

31815

f 3I

__I

ON-BOARD COMPUTER

F 3

. I-I I E LI WHT/V 0 12 {I WHT/YEL 11 , I BLU

I I I I I

WHT /GRNN

BBB

I I I

HT/V IO

INSTRUMENT CLUSTER

I e7 I r40 BLK I, fi0 -T/GR .

WHT/VIO

TRANSMISSION CONTROL MODULE (EGS)

_-I

ELECTRONIC IMMOBILIZER CONTROL MODULE (EWS II)

I~ 1 1 IJ 9

3281 .M3 31815

WHT/VIO WHT/VEL

BlK

WHTIVIO

BODY ELECTRONICS CONTROL MODULE (ZKEIV)

WHT/YEL8

-. I

SLIP CONTROL MODULE (PBS)

0" O

w Y

F>-,

.1111

CRUISECONTROL MODULE

88981

16l

O EX1997

CONVERTIBLETOP CONTROLMODULE

SRSCONTROL MODULE

4 (NOTUSED)

1>_-

ABSCONTROL MODULE] HYDRAULIC UNIT (1997)

BLK

WHTIVIO

1 _I

AUTOMATIC CLIMATE CONTROLMODULE

ELE-90

ELECTRICAL WIRING DIAGRAMS

Data Link Connector 1998 Except 318ti

HOT AT MES ALLTI-I-,

HOTINRUN AND7SIlTART

I /

I FUSE F26

HOT IN ACCY, START~A .NO RUN

rI II

DATA LINK CONNECTOR

+ FUSE, FRONTPOWER DISTRIBUTION BOX / F46

USE ') 33

HOTATALLTIMES 16IJUMPSTART JUNCTION POINT LJ

820 OHMS

Y2Y -X--T B S 10 11 1 Y3 1 Y5116Y 7118Y 1'20

,3 4~

BRN/ORG

BFNN

+G202

ib G103

~I " G203

BLK/VIOIYEL

WHTIVICIYEL

,10 '11

l I

'12 ,13

BLU

)14

,15 1 16

GENERATOR

REDIWHT

OBD II CONNECTOR

TELEPHONE CONNECTOR

318 323, 328, M3

WHTIVIO ENGINECONTROL MODULE (DME)

WHTIYEL

I I

I __I

ON-B CARD COMPUTER MODULE

LI B I WHT T/GFN

WHTwHTIV~~

WHTIYEL111

I I I

I I I I I __

88 67 40 ~ 60

WHTlVIO(ORWHT/VIO/YEL

I I

INSTRUMENT CLUSTER

WHTIYEL BLK WHT/GRN(ORGRNIBLV WHT/VIO

TRANSMISSION CONTROL MODULE (EGS)

1---l

ELECTRONIC IM MOB'IZER CONTROL MODULE (EWS11)

I1 I~

11 9

323 .328 . M3 318

WHT/VIO WHT/YEL

BODY ELECTRONICS CONTROL MODULE (ZKEIV)

WHT T/V~l WHTIYEL

SLIP CONTROL MODULE

WHT/VIO

AUTOMATIC CLIMATE CONTROLMOD .LE

CRUISECONTROL MODULE 104718

CONVERTIBLE TOP CONTROLMODULE

SUPPLEMENTAL RESTRAINT SYSTEM CONTROLMODULE

L-1

ROLLOVER SENSOR

L-1

ABSCONTROL MODULE/ HYDRAULICUNIT

ELECTRICAL WIRING DIAGRAMS

ELE-91

Data Link Connector

1995 318ti DATA LINK CONNECTOR

25456 T1;S 3I

I I I

HOT IN STARTANORUN

,XIT

PUSE ,FRONTPOWER (DISTRIBUTION BOX R2B 1 J~,DA

`7' `~`(yy ,21 16,4Y5117 511

3 ul

~I ml

LI__ J

WHT/YEL

ENG NE CONTROL MODULE (DME)

L1 ,S

WHT/VIO

II ,II L__I

O ,2 WHT/VS

TRANS ISSIONCONTROL MODULE (EGS)

INSTRUMENT CLUSTER

I I I

I I

WHTIVIO

BLK

WHT/VIO

,IiI

I I

CONTROL MODULE (.WS II)

BODY ELECTRONICS CONTROL MODULE (ZKE IV)

I_WHTIV iT~I

I I

I SLIP CONTROL MODULE(ABS)

CRUISE CONTROL MODULE

SSSSS

SRSCONTROL MODULE

ELECTRICAL WIRING DIAGRAMS

ELE-92

Data Link Connector 1996-97 318ti

HOT IN START AND RUN

HOT IN ACCY . START AND RUN

'26E

F46 E

DATA LINK CONNECTOR IDISTRIBU ION BOX

LT6

7T6

910111Y314/15/16/17/18/19)20

BATTERY

08DII CONNECTOR

BLK/VIO/VEL

GENERATOR

I I I I

I I

2 60

I 7 88 ~ 87

IIII

WH7/GRN

ELK

WHT/VIO WHTIYEL

WHT/VIO

WHT/YEL - 3 jI

ENGINECONTROL MODULE (DME)

I I

BOAROCOMPUTER

87E L

I I% 40 ELK I I% 60 WHT/GRN I I BS HT/VIO/V I I1 I-_-I

WH7T/G

~I WHT/V~L 11 I

I I I I WHT/VIO 12 I I L--I L

TRANSMISSIONCONTROL MODULE (EGS)

INSTRUMENT CLUSTER

HT/VII

I 1 11 I

I --I

WHT/VIO

ELECTRONIC IMMOBILIZER CONTROLMODULE

BODY ELECTRONICS CONTROL MODULE (2KE IV) WHT/VIO

I -- II I

SLIP CONTROL MODULE (PBS) 3 17

CRUISECONTRIL MODULE 88963

SRSCONTROI MODULE

ELECTRICAL WIRING'DIAGRAMS

ELE-93

Data Link Connector 1998 318ti

HOTINRUN ANDSTART

HOTAT ALLTIMES

FUSE F26

HOT(NACCV . STARTANDRUN

FUSE 33

DATA LINK CONNECTOR

FUSE ,FRONT POWER I DISTRIBUTION BOX F46

RE= "

BAN

BRN

FN N " BB ~I G201

)6 ,7

II II

RED

f I I I I I

OR" " ~ ~I~G202

BATTER

BLK/VIO/VEL

)9 ,10 I ,11 1 12

J I

BLU

'13 / )14 ,16 I ,16

GENERATOR

RED/WHT

OBDII CONNECTOR TELEPHONE CONNECTOR

I I

60WHT/GR

1 1 88

_WHT/VIO

WHT/VIO

WHT/VEL

87~ WHT/VEL

ENG NE CONTROL MODULE (DME)

I I II I L__I I

877

BOAPDCOMPUTFR

WHTIVEL

SILK 60

WHTwTIYE1

I I I L __I

WHTIGSN

WHTHT/G

SBA

INSTRUMENT CLUSTER

TRANS ISSIONCONTROL MODULE (EGS) WHTTIVIO BLK

I I

ELIECTRONII IMMOBILIZER CONTROL MODULE

CRUISECONTROL MODULE

104717

SUPPLEMENTAL RESTRAINTSVSTEM CONTROLMODULE

SLIPCONTROL MODULE

ABSCONTROL MODULE/ HYDRAULIC UNIT

BODVELECTRONICS CONTROL MODULE (ZKEIV)

ELE-94

ELECTRICAL WIRING DIAGRAMS

Engine Cooling HOT AT ALL TIMES

HOT IN RUN AND START FUSE F16 5A ORj B

FRONT POWER DISTRIBUTION BOX

FUSE pq1 30A

X' W16

22 X10018 RED/~ GRN

I GRN/1 ELL

RED/ GRN 8

30,77 HIGH SPEED RELAY

GRN/ BIU I 4

GRN/~ RED 6

87a

B6b

NORMAL SPEED RELAY

3 1992 BLWI GRY

BLW DUN TEMPERATURE SWITCH

ASOVE99 DEGC

AUXILIARY FAN MOTOR

ABOVE 91 DEGC AGOlE j)BELOW 18 BAR J 15 BAR

BRN 126 12

BELOW 21 BAR ABOVE 26 BAR

BLWGRY

ml ml

BLWG~~ X6000 ENGINE CONTROL MODULE (DME)

ABOVE 30 BAR BELOW 1 .5 BAR

GfIS

II . .1 BLU/BLK

PRESSURE SWITCH

BLWBLK 22 X18157 INTEGRATED CLIMATE REGULATION CONTROL MODULE

126

87581e

HOT IN RUN HOTAT ANDST_AR_TA LL_TIMES T- -j 7---FUSE FUS~ DISTRIBUTION BOX 16 41 I 30A-I (- SA _12Y 22Y

BOX I

TEMPERATUBE SWITCH

AS OVE99 DEGC

3'~'1

ABGVE91 DIEGO

> Y~ ~ml

ABOVE 30 BAR

BELOW 1 .5 BAR

BLK/GRY BELOW 21BAR

BLU/BLK

a O

INTEGRATED HEATING AND

_=FROLMODULE I I

BLK/GRY BRN

318

BLK/GRY 85 BLK/BL48 BLK

BRN

325

85 48, E

ENGINEC

38LU

MODUOLE

2 BLK/BLU

BLK/BLU

,S YSTEM ISSIONS (W/ EGS)

AUXILIARY FAN MOTOR

BLK/RED 10, I

'i_--

VARIABLE CAMSHAFT CONTROL MODULE (B Cylindar only)

Q (PIN NUMBER 5 IN LATE 1995) ® (PIN NUMBER 2 IN LATE 1995) G110 80490.

1993-95

ELECTRICAL WIRING DIAGRAMS

Engine Cooling HOT IN RUN A_NDSTART DISTRIBUTION BOX

;2Y

16_SE I _

HOTAT ALLTIMES 40 48U5E I

FUSE BOXY

BLU/BLK

BELOW 15 BAR ABOVE 18 A, A/C PRESSURE SWITCH

AUTOMATIC CLIMATE CONTROL MODULE BLU/BLK 11,1

2 BLK/GRY ~G BRN ~ i)ASOVEBBDEG C (1 .8L)ABOVE 99 DEG C /28L) 2)ABOVEBODEG 91 D EG ABOVE D (2 .BL) BLK/GRN

H BRN DOUBLE TEMPERATURE SWITCH

AUXILIARY FAN MOTOF

104497 .

HOTINRUN HOTAT ANDSTAR_T_ _ _ _ALL_TIMES FRONT POWER I - ' FUSE FUS~ DISTRIBUTIONBOX 1 16 41 L GD_A_ 1 5A - _ 12Y 22Y

DOUBLE TEMPERATURE SWITCH 1Y2Y

1996-98 6-cylinder

89017 .

ELE-95

ELECTRICAL WIRING DIAGRAMS

ELE-96

Transmission Electronics 1992 3181, 318is, 3251 & 325is

HOTATALL

DATA LINK CONNECTOR

TIMES

WHT/1110 WH 7VEL

~~ 1 ~~

COMPUTER DATA LINES SYSTEM

RED

6 GRV/B HT S RN EGS WARNING LP I~ 1K 21 W I_ FUELCONSUMPTION ___ X16

SHIFT LK SOL

GR RNGSIGL3 TIM EASSIG(FL)

FL PMP FLY CTRL

FU BE F26 161L

121l 6

GRN/ WHT

FUSE F28 -xiDD-tz

YELIGRN BLU/WHT

VID/ E L 1I1

WH7/BLK "

)1 6

GND OUTPUTSPD(+)

OILTPSIG(+)

RxDDATALK

BRN BR`N

" BRNI

I I I

1 -

G200

6 BRN/BLK ,27 1 B RED

BATTERY VOLT

1 VEL/WH7

MAN MODESIG

~J32 3BR .IW .T

GO RNG BIG L4

NCA

RED

GRY

110

37 RED/WHT

VOLTSUPPLV

6BLU 9 BLU/RED

TCCSOLCTRL SKPDLPOSIT . . HVO CTRL (+)

BRN/ VIO

41 GRY ,42

VIO

'44 / 45 VIO , '46 ' vi7 14 8 DR.

BANDSOLCTRL

SOL VAL 1 CTRL

GRY/RED I

NCA

NCA NCA

OIL TEMPERATURE S ENSOR 1

xIiS21 YE L 1 NCA NLA BLK 2

SPEED SENSOR

"511

TRANSMISSION VALVE UNIT

FLPT

MPRLYCTRL

1117IDKV FUELCONSUMPTION 48 I 64

OMPCTRL

GRV/ RED

BRN/WHT

_ 2 r (OUTPUT

I I

DINNER

INTERIORLIGHTS SYSTEM

BLU/

1 4

BRNI

TRANSMISSION CONTROL MODULE LEGS)

BRNIORG

" BRN/ORG

GRV/VE L RE.'

TOROUE CONVERTER C LUTON SOLENOID VALVE

I J ENGINE CONTROL MODULE (0E) M

5BRNIORG

TPSSIGNAL

BAND SOLENOID

NCA

3I 4

U BRN/GRV

Y53 14 SRN

SOLGNDCTRL

GRNIGRY

51 12

NCA

NOA

BLKIBL

PRESSURE REGULATOR

BR IDRNVERANGEP/N

INSTRUMENT CLUSTER SYSTEM

NCA

SOLENOID VALVE2

NCA

BLK CLR

43 GRN

SOLVAL2CTRL

SHIFTLOCK

" --

__J

NCA

0 RED

HVD CTRL(-)

BLU

B RN/ O RG W HT/B L K

ION-BOARD COMPUTER

WHT/BLK6'

X1DZt I

SOLENOID VALVE1

BLK

68RNIOMG

GND

.ONI

BRN

" BRNI -AL

88905

GRN

4 VEL/GRN 5BRN/VID

S-PROGBUTTON SHIFTLKGND

PROGRAM SWITCH

NCA

3 0 GRV/VEL

KICK-DOW N SIG

MAN

-v

9GRV/B RN

FAULTINDBIG

ORG

I I I I II

4 ~6WHT/VEL

GR RNG SIG L2

LIGHTS DR

BLU/RED

BRAKE LIGHT (ITCH SW

II -

3 BLUIBLK

GRRNGSIGLI

2 T

BRNIGRY

BRN/I GRY' 8

1BLK/BLU ~22 ELK

P/COOMPON

_ ZJ

23 ((NOT %69 USED)

19 BR N 20 V EL

{5 COMPRESSOR CONTROLRELAV

FRONTPOWER DISTRIBUTION BOX

VEL/BLU

17 CLR 16 NCA

OILTEMPSIG S PDSENSSHD

r ___J

I I I

SYSTEM

5BRNIGRV

B KSWTESTSIG

I II

BRAKE ( LIGHT (SWITCH

_ _ J II I II

ENGINEOL _CON7R MODULERELAY

BLK/BLU

22 NOT USED)

13 WHTIVIO 14 BLK

T%DDATA LK Do TPUT BPD (-I

' 167q

ENGINE CONTROLS SYSTEM YSTEM

BLU/R EO

-XK

RED " WHT

" VEL/GRN

RED/WHT "

VIO/VEL

OR ./ GRYI

G123

r _ _ _ _ _ _ 1 _,

RED/WHT

16-J xi .DOiB

12 YELIWHT

M-PROGIND

BRN

10 YEL/BLU 11 ELK

A -PROGIND

BR N/GRV

7 9

S-FROG IND

B+ JUNCTION

HOT IN ACCV,RUN &START _JFRONTPOWER FUSE DISTRIBUTION BOX F48

BRN

VEL/BLU

IG TIMING INT

WHT/ BLK

VIO

~,3

~~~.

INSTRUMENTCLUSTER

AUTO MODE SIG

HOT IN SUN &51ART

HOTINRUN &START

G201

BLU/BLK

GRNIWHT

BRN/6LKI J~G7-3 'I

OFF E%LEGHOS,'

BRN/ BLK

GRV/VEL~(EARLV PROD) TRAN SMISS I ON BLK (LATEPROD) POSITION 1 INDICATOR KICK LIGHT DOWN SWITCH

BRN/ ELK I I

NCA 1

8 e6

I I

II I I I) -

I) CRUISE CONTROL STARTER RELAY MODULE (TEMPOMA7)

SYSTEM BRN/ GRY 1 I I

EGSA4S310R L1 L2 L3 L4 X1070 I I

II _ ON-BOARD COMPUTER (M ULTI-FUNCTION OLOOKI

BLU/VEL " BLU/YEL

D 3

0 0

D 1

1 1

CLOSEDIN REVERSE POSITION AUTOMATIC TRANSMISSION RANGESWITCH

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL

WIRING

DIAGRAMS

ELE-97

Transmission Electronics 1993-94 318i, 318iC & 318is

DATA LINK CONNECTOR

r [-

W~ 20, WHT/vI0

L COMPUTER DATA LINESSVSTEM

WHTT/EEL

HOTINRUN &START ~FS US E I F26

HOTATALL TIMES IB+ I ~ I PUONICTION

HOT IN RUN &START

L 1 __ " - Y - - - 16 GRN/I WHT "1

REO

HOT INADDY, RUN &START

FUSE F2 8

FUSE F46

SA X19077

1 -J X14416

32 " VIO/VEL I

" --" - " """

GRRNGSIGL3

(

10 YEL/BLU

M-PROGIND

13 WHT/VIO 14 BLK

TKD DATA LK OUTPUTSPO(-)

---

1& NCA 1 S BRN

GND OUTPUT SPD (+)

20 YEL

3B~2

GRN I

--------"

--------

NOA

I VI O

2i, NCA

r I

III

I _~J 4 BFNj

LU/BLK

BLU BRN

NCA

SILK CLR

NCA NCA

BRN(

J-

G200

BLK

30 GEV/VEL

SOLE NOIO VALVE2

HYDRAULIC PRESSURE REGULATOR

BAND SOLEN010 TORQUE CONVERTER CLUTCH SOLENOID VALVE

OIL TEMPERATURE SENSOR

SPEED SENSOR

(

BRN( VIO

VIO

NCA

SOLVAL2CTRL

WHT/BLK

I ~

SHIFTLOC K

BLKIBLU

BRNIGRY BRN/BLK

I I I I I

-(ID=IVENMODUE(DME)

(0-a

TRANSMISSIOI VALVE UNIT

1 IFLPMPRLVCTRL 11 17IDKV PUELCONSUMPTION 48 I A/CCOMPDT RL B4 ~ IIGNTIMINGINT 65

SRN/ORG

r ---

BRNIGRN

ION-BOARD COMPUTER

NCA

X651fi

WHT/BLKSf

r5 --

XflS21 NCA Y-1

V / MANMODESIG I ,3 1 u32 1~38RN/WHT GRRNGSIGL4 L/GRN } VE S-FROG BUTT ON 734 5 BRN/VIO SHIFTLKGND BR~ / ORG GND e36 ~3 7 R / VOLTSUPPLY l~ & BL U TCCSOLCTRL B B~ LU/RED BK PDL POSIT . 00 F~ HYD CTRL (+) 41 HVDCTRLI-) G}~ '42

BANDSOLCTRL

NCA

BRNIGRY

/2 6RED ,2 0 G FY IBRN

KICK-DOWNSIG

9 I

GRV

BRN/ I GRY 3_,~_ _ BRAKE LIGHT (SWITCH

4 HT/VEL ~BW RxD DATA LK j2 126 BRN/BLK GRRNGSIGL2 ~ ~ BATTERYVOLT FAULTINDSIG

NCA

I 8 -~

RED --

22 BLK

GRRNG SIG L1

EXTERIOR LIGHTS SYSTEM

BL U/RE D

SOLENOID VALVE1

1BLK/BLU ~-

AID COMP ON OILTPSIG(+)

COMPRESSOR CONTROLRELAY

oRG

BLU/RED(

----

,17 CLR

OILTEMPSIG

I i

S r_ I I 67A L___JI ENGINE CONTROL ,I MODULERELAY L_ _j FRONT POWER DISTRIBUTION BOX

ENGINE CONTROLS SYSTEM

23 (NOT n94 USED)

1fi

SPDSENSSHD

FUELPUMPRELAY

RED/I WHT

BRAKE 'LIGHT WIT(

I ~+ I 1 /

_RED/WHT(

VIOL VEL

BLU/REO (

5BRN/GRY T

BK SWTESTSIG

VELIBLU

11 BRN/GRN 12 VEL/WHT

FLPMPRLYCTRL

22 (NOT Xfi9 USED)

WHT/BLK

MEAS SIG (FL) A-PPOGIND

BLU/WH7

5- --

J-

6723

BRN/ GRY

BRNIGRN

BLK/BLU

W/OCCM

FRONT POWER DISTRIBUTIQN00X

VIO/VELr

GRN/ GRY

W /CCM 15-GRV/B~RN~ qED/WHT I~ EGS WARNINGLPI~ W= VIO/j I FUEL CONSUMPTIO~ 21 VEL %1R INTRUMENTCLUTTER _ BRAKE WHT/ (LIGHT BLK BRN . iSWITCH 1 V IO GHIFTLKSOL VE L/BLU BRN AUTO MODE SIG IGTIMING INT

'48 7

SOLVALICTRLI~ ~ X49

I pso

GRVIREO

I "

51 / P2 SOLGNDCTRL TPSSIGNAL

P 4B/5

GRYT RED

J DIMMER

rO UTPUT _ _ _

INTERIOR LIGHTS SYSTEM

5BRNIORG I

TRANS MISSIONCONTROL MODULE (EGS)

VEL/BLU

BRN( " BRN

T G123

BRN/ BLK

BLKk'/ 1

BRN( BLK

I-~I KICK 1 1DOWN SWITCH

EXTERIOR LIGHTS, SYSTEM

BRN(

G201

B t I

I I

CRUISE CONTROL I -I MODULE STARTER RELAY (TEMPOMAT)

X1974 I

I _I ON-BOARD . .COMPUTER (MULTI-FUNCTION CLOCK)

BLU/YEL 3 " (-~ CLOSEDIN REVERSE POSITION EG S A4S 310R

BLU/VEL

.RN/ GRY

2B t

BANr

1 71706

GRNlWHT

OFF ORG

GYEL1

TRANSMISSION POSITION INDICATOR LIGHT

BLU/BLK

BRN/BLK

BRN/ORG

REVD I

L7 1

L2 L3 L4 1 0 1

0 3

0 0

0 1

1 1

2 1

AUTOMATIC TRANSMISSION gANGESWITCH

ELE-98

ELECTRICAL WIRING DIAGRAMS

Transmission Electronics 1993-94 325i, 325iC & 3251s

DATA LINK CONNECTOR

I LLJ

JUNCTION (POINT

W, HT/VIO WHT/VEL

COMPUTER . DATA LINES SYSTEM ~,

HOTINRUN HOTINRUN &START ..y111CCC --- - - - - &START I1'

HOTATALL TIMES

1 5LK 15~ WHT 20

(

HOTINACCY,RUN &START , ,1111~~~ FUS~ FRONTPOWER I DISTRIBUTION BOX F28 B / F46 E _16A - I X19oIz --- s2 X]9llifl VIOIYELT

F26 B 10

1z16 ----

GRINGRN/ ---WHTI GRV

RED

-------I B GRV/BRN EGSWARNINGLP 120 VEL/WHT I CRANKRPMSIG 1 WHT/BLK I FU ELLONSUMPI . L ~ -----j X1fi

" I GRN/I WHT

VIO/YEL(

WILCM

RED/WHT

Br \I87---~

E NGINECONTROL MODULE RELAY

I I I

WIOCCM

VIO VE L I 1 JJJ _ , , _BRAKE (LIGHT ( SWITCH I

GRN/ WHT

ENGINE CONTROLS SYSTEM

RED/WHT

SL .I.LUI

L- -J I L_ _ Br

VI0I~ VELA( 1 .

COM-PRESSOR I CO NTROLRELAY ----J FRONTPOWEP DISTRIBUTION BOX

BRAKE LIGHT SWITCH z̀ ``yyy

SLUIREDI

SPROGIND GRRNGSIGL3 TI SIG (FL) APROGIND RPM SPDSI M-PROGIND T.. DATA LK 0UTSPD() BKSWTEST

7 VEL/GRN & BLU/WHT WHT/BLK

13 WHT/VIO n-Ir--14 BLK

---

------

5 BRN/GRV

---

GRN

SYSTEM

-__----_

NCA

----~

RED GRV

NCA

I I

VIO

NCA

" ~

ORG

f EXTERIOR LIGHTS

BLU/ BD

BLU/ RED

L/BLU 23 (NOT xBg{USED)

I1 BLK

OILTEMPSIG >17 OLR SPDSENSGND

BLUIRED

10 Y ELI . LU

SL U/REDI

19 SPIN

SOLENOID VALVE

SOLENOID VALVE2 HYDRAULIC PRESSURE REGULATOR

BAND SOLENOID

CONVERTER

X27 SATTERYVOLT FAULTINDSIG KICK-ON 3 1 G

RED 9 GRY/BRN

30 GRV/VEL 1YEL/WHT

MANMODESIG

w32 I 3 BRN/WHT OR PING SIG L4 S BVERL N S-PROG STN 6 GN/VRIO S HIFT LK GNO 6BRNIORG GND 7REDIWHT VOLTSUPPLV S BLU TCC SOL CTRL 9BLU/RED BK PDL POSIT. ORED HVD CTRL (+) GRY 41 HVOC7RL(-) ,42 SOLVAL2(a) BAND SOL(t)

SOLVALI

TRANSMISSION

r II

WHTI BLK 6

ION-BOARD COMPUTER

X1071 - _ BRN/ ,ON-BOARD ON-BOARD GRYI(COMPUTER I (MULTIFUNCTION X"1-07.0 CLOCK) VIO

BRN/ORG 11 WHTlBLK46ILHROTTLEVALPOSIT,

L -J NCA

BLK 47

(CRANK RPM SIG . BLK/BLU 48 " CIA/C COMP. CTRL . BRN/GRV67 (ION TIMING INT . BRN/BLK 81 IDRIVERANGEPIN

SHIF7LOCK

43 GRN ,44

BRN/VI0 2I

/45VIC

GRN/RED

'46 I

IFUELCONSUMPTION

ENGINECONTROL MODULE (DME)

NCA

" GRN/PEp2rOUTPUT ,DIMMER ~~---J GRN/RED

r7 4 ORO 8

INTERIORLIGHTS SYSTEM

GRN/GRY

GRN/WHT

X53 SOLVALCTRL TPS SIG

4 BRN BBRNIORG

TRANS MISSIONCONTROL MODULE (EGS)

BRN/ORG

BRN BLU/ GRN/ ~ 5 GRN/WHT RED AUTO+ OFF MANT

PROS RAM SWITCH

71793

YEL/WHT

TRANSMISSION POSITION INDICATOR LIGHT

.RN(

17 B RN'

" BN(

BRN

BBL~K

GRY/ YEL

m `~ G123

BLK

DOWN SWITCH

NCA

11 G201

BLK

"J SRN/ BLK

EXTERIOR LIGHTS SYSTEM

16 X .]-B]$-S I 70 I

I I I - I

I I I -I

STARTER RELAY

CRUISE CONTROL MODULE (TEMPOMAT)

I - I

INTEGRATED CLIMATE REGULATION CONTROLMODULE

BRN/ BLK

BLU/ YEL 3 f

YEL

EGSA4S310R

26 S6-1

_211_31 L4

1 1

1 0

O 0

1 0

D 3

0 0

0 1

1 1

2 1

1 0

0 0

1 1

1 0

P R

CLOSEDIN REVERSE POSITION AUTOMATIC TRANSMISSION RANGESWITCH

I I I I I I

ELE-99

ELECTRICAL WIRING DIAGRAMS

Transmission Electronics 1995 3181, 3181C & 3181s

15, VVHT/VEL

'IpOIINTION L ~J

WHT/

I " 1

WHT/GRN/ YEL

EGS WARNING IF 15 21 WHT/BLK FUELCONSUM PT=O~ _ _ _ _ _ _ Xlb INSTRUMENTCLUSTER 1

SHIFT LK SOL

IGTIMINGINT

GRNI WHT

BRN

YELIBLU

BRN

BRN/ GRV

G123

GRN/ WHT

VIO/~ YEL 1

OFN WHT

I I

_ 1 -

SPROGI NO

VEL/GRN BLU/WHT

GRRNGSIGL3 TIMEASSIG(FL)

YELIBLU

71 BRNIGRN

FLPMPRLVCTRL

12 YEL/WHT WHT/VIO

M-FROG IND Tx-DATALK

14BLK

OUTPUTSPD(-)

19 BRN

GNO

20 YEL

OUTPUT S PD (a)

,26 1 5

GRN

I NCA

0200 1 T

SPY

NOA

VIO

NCA

BLU

NOA

BRN

NCA

BLK CLR

3 I 4'

SOLENOID VALVE2

REGULATOR

" r X3Plll -VIO 2 8-

TRANSMISSION VALVEUNIT

VIO

BLK/BLU

SHIFT LOCK

------I FLPMPRLYCTRL

1TIDKV FUELCONSUMPTION 48 I A/OCOMPCTRL 64I IIGNTIMINGINT BS DRIVE RANGE PIN -

BR N/BLK WHT/GRN/ V EL

ANT

I I I I I

END NECONTROL MODULE(DME)

1I NCA I

WHT/BLK BRN/GRY

NCA

xa53a BRN/GRN

OIL TEMPERATURE SENSOR

SPEED SENSOR

WHT/GRN/YEL

ION-BOARD COMPUTER

WHTIBLKGI

NCA NCA

TORQUE CONVERTER CLUTCH SOLEN010 VALVE

X8521 VEL A NCA INCA BLK 2

LOCK

s~srEM

X44

13 ~ I

GRNIG

GRV/RED

GRY/ RED

51 I f2

B RN/WHT

I OUT=U= JOIMMER

Ow BLU/

INTERIORLIGHTS SYSTEM

~P3 4BRN

BRN/BLK

5 WHT/GRN/VEL

0 "

TRANSMISSION CONTROL MODULE (EGS)

BLU/BLK

VEL/BLU I

BRN

BRN/. OF G123

BRN(

GRY/ YEL

TRANSMISSION POSITION N ICATOR LIGHT

BRN/ BLK

SRN/ ELK

EXTERIOR LIGHTS ( SYSTEM

KICK DOWN SWITCH

9_ _1 I I

25 I I

-I ELECTRONIC IMMOBILISER CONTROLMODULE

I I

-I

I I

MODULE (TEMPOMAT)

EGSA4S310R L1 L2 L3 L4 X]974 I I -I

ON COMPUTER (MULTI-FUNCTION CLOCK)

2IE R Y

BLU/VEL 3

BLU/VEL

GRNI DRY

BLK

" . R (

G201

GRN/WHT

BRN/BLK

BRN/ORG

"Y' RED

88958

NCA

T ~'

45 VIO .AND

PROGRAMSWITCH

SOLENOID VALVE,

PRESSURE UE,

RED

TPSSIGNAL

NCA

I I

BATTERVVOLT ~ f ~ FAULT DSI . X30 GRV/VEL KICK-DOWN SIG ; 1 YEL/WHT MANMODESIG X3 1 S G RRNGSIGL4 4YEL/GRN S-PROGBUTT' N G B SHIFT LK GNO ~BBRN/ORG GN0 ED/WHT 2 VOLTSUPPLY & BLU Ri TCCSOLCTRL 9/ Ba BK POL POSIT . 40 RED HVDCTRL(a) ~GRV 41 HYO CTRL (-) )42

SOLGNOOTRL

GRNI

W NT/YEL

SOLVALICTRLI ~ X49 1 ,50

O RG

26 BR /BLK

BRAKE LIGHT ISWITCH

-W IJ 4 BRNT "

1238LU/BLK

GRRNGSIGL1

I I I `L_ -_J I ENGINECONTROL I MODULERELAY 5r

___

L_--__-J FRONTPOWER DISTRIBUTION BOX

EN INE CO NTROLS SYSTEM

BLU/REOI BLU/Ep " i EXTERIOR LIGHTS SYSTEM

GRY

26LK

OILTPSIG(t)

-J COMPRESSOR CONTROLRELAY

.F' FN/

1DLK/BLU ~-

A/CCOMPON

WHT1I-1

---

1T OLR 1B NCA

BRAKE LIGHT SWITCH

23 X83(NOT 3 USED)

)

OILTEMPSIG SPOSENSSHO

BLU/RED

SBRN/GRV I

BK 5 W TEST SIG

VIO/~ YEL 1

I RE-/WHTJ . . -_ " . RED/WHT I REDII I

2 BLUIREDr

VEL/GRN 22 " (NOT Xfi9 USED,

WHT/BLK 10 YEL/BLU

A-PROGIND

SOLVAL2CTRL

2 BLUIRED

I _J j

FUELPUMPBELAY

BLKIBLU

W/DOOM

_BRAKE (LIGHT I SWITCH

85 -

VIO/VEL

W/CCM

BRN/GRN

VIO/VEL

GRN/ GRV

WHT/GRN/ VEL

ASCSIGNAL

RXDDATA LK

HOT INADDY. RUN START -IFRONTPOWER DISTRIBUTION BOX F4BE

5-_ 5-J Z32YZf1001.8 ----

WHT/BLK

WN T BLK

VIC

A UTOMODESIG

GR IN . SIG L2

ANTI-LOCK BRAKES SYSTEM

W/A50 ONLY

GRV/BRN

HOT IN RUN &START

rr~ Bt

~1 .VNT/VI

COMPUTERDATA LINES SYSTEM

HOT(NRUN & START

HOT AT ALL

DATA LINK CONNECTOR

P R

2 1

CLOSEDIN REVERSE POSITION AUTOMATIC TRANSMISSION RANGESWITCH

ELECTRICAL WIRING DIAGRAMS

ELE-100

Transmission

1995

DATA LINK CONNECTOR

WHTIVID W.TjvI . * COMPUTER 4 DATA By, LLINES NEE 'I , W~ HT/YEL WHTIYEL " " SYSTEM TEM ~ --------. 8

r r -EGS 1S WARNING - - - T1_1 LP-

I~ !~,

SNIFTLKSO sHU ` TLKSO

S-FROG IND GRRNGSIGL3 GFFNGSIGLS TI SIG T1 SIG(FL) UFQ A -PROG IND A-PROG RPMSPDSI RPMSPDSU M-PROGIND M-PROG IND TxDDATALK T~D DATA LK

OR GRN/ WHTT* i

BKSWTEST *OILTEMPSIG SPDSENSSHD PDSENSSHD .No OUTSPDAIC(fO) OUTSPD(+)

W /CCM

GRN/ RNI] WHT

VEL/GRN YELIGRN

BLU/WHT ILUIWHT

WN7/BLK 10 YEL/BLU 1,

VEL/GRN YELIGFN

YEL/BLU YELIBLU

---

5BRN/GRV 5BRNIGRY ), 6

--- -_- - I L

-I

177 CLR ) 18 18 NCA 19 BRN R" L 20 1 Y-E YEL '

7BLK/BLU v ii

AICOI X22 BLK TEMPPSIG SIG * OIL OILTE ~ 1~ 3 BLU/BLK GRRNGSIGL, R RNG SIG Ll

-_---- - -

I _

_ I

FRONTPOWER DISTRIBUTION BOX

BLUI BLU/ RED

" i

BLU RED BLUIRED

EXTERIOR LLIGHTS GHTS SYSTEM

i'2 43 GFN ~1 GRN ,44 :4, I OSVIO VIo

VIO

BRN/VIO

NCA

Vio VIO

rtY

BRAKELIGHT 'SWITCH SWITCH

NIA

T T 2 NO A LY y X8518

WHT/GRV/YEL11 WHT/BLK 46

BRN/GRY 57 BRNIBLK S1

r. '

NCA

GRN/WHT

YELIWHT

I I I

IDRIVERANGEP/N ( L__ ENGINE CONTROL MODULE (DM E)

BRN/WHT

8 O1

B BLU IINHT

BRNIBLK

BLUIBLK

BRN/ BLK'

14~

DRY] YEL

GRN' RED

AUTO AUTO

TRANSMISSION POSITION INDICATOR LIGHT

N -oll OFF

BRN'

BRN '

NCA' t G207

BRN/ BL.

BLU/ YEL U'

EXTERIOR LIGHTS SYSTEM

BRN/' BLK

I I I

I I

TD -I

INTEGRATED CLIMATEREGULATION Do NTROLMODULE

I I

I -I ELECTRONIC CoIMMOBILISER NTROLMODULE

I I I

I - I

CRUISECONTROL MODULE (TEMPOMAT)

BLU/ VEL 8

EGSA4S310R L7 L2 L3 L4

25 J, KICK DOWN SWITCH

1 T BRN B

" J

BLK .123

P R

D 8

0101110

IIGNTIMINGINT.

BRNI ORG

Iq/C COMP . CTRL .

GRNIGRV

=INN

TRA TRANSMISSIONCONTROL missioNcoNTROL MODULE 7S (EGS) UEGS)

IlHROTTLE VAL POSIT.

ANTI-LOCK BRAKES SYSTEM

INTERIOR LIGHTS SYSTEM

TRANSMISSION VALVE UNIT

IFUELCONSUMPTICN BLK47 ` ICRANKRPMSIG .

SHIFTLOCK

P X53 I SOLVALCTFLI ~44 BRN SOLVALCTRLI 5 WHT/GRV/VEL

88931

NCA

1 L 1,

PROGRAM SW ITCH

GRY GIY

j zJ

GRN/RED

MA NTT

RED RED

" GRN,REp 2 LOU-T--PUT--'DIMMER J

GRNIRED

,L fi Yi~

WHT/ BLK 6 FION-BOARD COMPUTER X o7I _ BRN/ ~C N -BOARD ORY 1 COMPUTERR I(MDL7IFUNCTION X1DZ0 - ._ J CLOCK)

r77 48 ORG ~ 8 oRG v49 1 fo ,50

8fi

----, 7

BLK-

68RNIORG J ^' ~ L^ ONO ~68RNIORG 7REDIWHT VOLTSUPPLY JIREDIWHT VOLTSUPILY ~~B EBLU TCCSOLCTRL J11L 9 BLU/RED ./RED BK PDL POSIT . .KP.LPOSIT GRED - - --- HYDCTRL(a) HYD TRL(+) 41GRY Ry HYD CCTFL C TRLI) I-) ,42

SO LVALI

GRIN

RED BATTERVVOLT1~8 BATTERYVCLT f'8 ~99 GRYIBRN PAUL X, 30 GRY/VEL FY/YeL KICK-DNSIG -NSIG . ~D 1YEL/WHT MANMODESIG ANMODESIG X32

BANDSOL(a) BANDSOL(l)

WHT/VEL ~5 WHTIYEL RKDDATALK ~ f~" X26 111!BLK BRN/BLK GRRNGSIGL2 GR A No S I G L2 n X27

SOLVAL2(a) SOLVAL2

B6r, I I85 L___JI COMPRESSOR I CONTROLRELAY

BLK/BLU' BLK/BLU

'III 1

BRAKE LIGHT SWITCH

ENGINECONTROL ENGINE Moo CONTROL ULE RELAY

BRNIJ BR . R~y N/~ G 3Y _ _

J _J .J .

r_____

--- - - - -- -------- - - - - -

o- - -

J . , J .-

_ A RED/WHT FEDIIHT I 5 " i~ F87 r7AT - -

E2 BLUIRE DI BLUIR

BLU/RE01 BLUIRED

23 UNOT OT X6g USED)

BLK

,22 YEL/WHT YEL1WHT 18 WHT/VIO

WHT/ BLK./ 8L

(NOT (NOT)

USED) %69 USED

VVIEIIILO/I L

ENGINE CONTROLS SYSTEM

RED/WHT

Wjo ~CM W/O CCM

VIOL VEL _ _BRAKE (LIGHT 'SWITCH I I

WHT/GRN/VEL WHT/GRNIYEL 7

VIO/YEL' V1.jYELj

2 .BLU/RED' BLUIREof

LLKT'V I-) ~j14 BLK

O UTSPDI) -

GRYIBRN HT ~N

BRN/GRY 11N/GRY

IS TIMING INT

325is

VIO V"o YEL/BLU Y1L11LU

AUTO MODE

ASCSIGNAL

HOTINACCY,RUN & START .y7111~~~ ~FRONTPOWER I DISTRIBUTION BOX I / F2fi E F28 E ( F4fi E LA T, 1 .5A_ ,101=______ __ ______ _I 3 2X7.0018 X1DQ1-Z 12 76 V10/Y GF~j -1Y`E L GRN/ GFN/ GRN/ " WHIT GRV

RED RED

IPOVEL/WH7 20 YELIW "'Y"' CRANK=1 CRANK ELC RPM SIG 181 WHTIBLK WHTIELK FU ELCONSUMP F`,`

325iC

HOTINRUN HOTINRUN START &START I -'''II~~ --~~~

HOTATALL TIMES ~Br r JUNCTION NCTICN I 'POINT L JJ

1 51-1 15 WHTYEL 2D 20 WH WHTIVIO

3251,

Electronics

~~ CLOSEDIN REVERSE POSITION AUTOMATIC TRANSMISSION RANGE SWITCH

ELECTRICAL WIRING DIAGRAMS

ELE--101

Transmission Electronics 1995 318ti

DATA LINK CONNECTOR

20 WHT/VIO

EGSWARNINGLJ

INSTRUMENTLLUSTER

SHIFT LK SOL AUTO MODE SIG IG7IMINGIN7

WH7/~ "

HOTINRUN &START

r FUSE I ~ F28

WHTT/VIO

COMPUTER DATA 1 LINES SYS7EM ~ '1

HOTINRUN &START

HOTATALL TIMES ~ Ea r I ~Ir- " ( JUNCTION JFOIN7 L

L3r-0-__ 2 I 16 GRN/ WHT

RED

FRONT POWER (DISTRIBUTION BOX

ELS F28 E

D 3

0 1010 0 0 1

1 1

I "

DEG

GRN

B I

RED

9 I

DRY

VIO

2 I

.'BLU

7 I

BIN

ELK

6723 >-

----

BRN/GRV3 X0

18 NCA 19 BRN

GND

20 YEL

(N OT USE D)

-I

16LK/BLU ~-

A/CCOMPON

2BLK

OIL7PSIG(a)

'27 ' e RED -~ BATTERYVOLT 9GRY/BRN FAULTINDSIG 30 GRV/VEL KICK-DO W N SIG 1 YEL/WHT MAN MODESIG X32 l 3 BRN/WHT GRRNGSIGL4 ,34 I S BRNIVIO SNIFTLKGND 6 BRN/ORG GND 7 RED/WHT VOLTSUPPLY 38 BLU TLCSOLCTRL gBLU/RED BK PD L POSIT . 40 RED HYDCTRL(a) 4 1 GRV HVDCTRL (-) ~42

I 11

T 1

%1071 --_j

I BRN/ VIO

VIO

43 GRN

SOLVAL2CT RL

1 -

NCA

VEL ~~

Ir'` 0 bi I .c2 ~N53 I 4BRN

G RY/I YEL( l

2,1,

OFF YEL/WHT BRN MAN

89077

SPEED SENSOR

NCA TRANSMISSION VALVE UNIT

11~IEL PMPRLYCTRL 17,I DKV IFUELCONSUMPTION BLK%BLU QB BRNIA/OCOMPCTRL

~WHT/BLK .

I I I I

IIGNTIMINGINT

IDRIVERANGEP/N~ -

SHIFT LOCK

ENGINECONTROL MODULE LOME)

NOA

BRN/WHT

2OUTPUT_JDIMMER -INTERIORLIGHTS SYSTEM

GRV( RED

GRV/ RED

\'~

PROGRAMSWITCH

XB52L NCA 1

8 O~

WHT

BLU/-

BRN/BLK

' GRNIWHT

NCA

BRN/ORG

ON-BOARD COMPUTER J(CENTER

GRV/RED

BRN

MAN

BLK

SOLENOID VALVE1

GRN/GRY

1 "

BEN

BRNj " BRN( 1 G201

TRANSMISSION POSITION INDICATOR LIGHT

E%L EGHOS f B LU~YEL

O RG

BLU/ BEN / 1 SYSTEM G123R I ED I ELK T HNI BLK( BLUIVEL BBLK S %1a D 7 26 I JJJ/ . KICK I (N OT US ED) I ~I GOWN SWITCH I I I I CONTROL MODULE

NCA 1

87A ENGINECONTROL MODULERELAY

SOLENOID VA L E2

%851fi

NCA

__ .

r WHTIBLK41

COMPRESSOR CONTROLRELAY

FRONTP0WER DISTRIBUTION BOX

77 CLR

OUTPUTBPD(r)

AUTO

TI I

REOIW

BRN/GRV BRN

OILTEMP SIG SPDSENSSHD

~\3 14

SLKIBLU EGSA4S310R

VIO

- --

FUELPUMPRELAV

BEN/ GRV

%16

SPIN

ALTO

'-_J

xLOeLz

.N . R1/

,8 BLU/WHT NCA GRRNGSIGL3 9 WH7/BLK TIMEASSIG(FL) 10 YEL/BLU A-PROG IND BRN/GRN FLPMPPLYCTRL 11 12 YELIWNT M-PROGIND 13 WH7/VIO T .DDATALK -fl 14 BLK OUTPUT SPD () ,10 BKSWTESTSIG5BRN/GRV

SOLGNDCTRLI

r q h~

BRN/GRN

CRU MODULE (TEMPOMAT)

I I

BLU/VEL 1 I I

I I

CHIMEMODULE

CLOSEOIN REVERSE >I71UN

I AUTOMATIC PUTRANSMISSION RAN GE SWITCH

ELECTRICAL WIRING DIAGRAMS

ELE-102

Transmission Electronics 1996-97 Except M3 (1 of 2)

HOTATALL TIMES

EGSA4S31OR L1 L2 L3 L4 P

D 3

0 0

0 1

1 1

~ FI PONLCTION

LLJ REDI

HOTINRUN 85TART

HOTINRUN HOT(NACCY,RUN EL 6START _________ _~Ba

FUSE

FUSE,DSORIBU

I I

ON BO%

I F26 F28 F4B I LIr'____~L s ._______~'BA J X1IIOSZX1907fl 32~I' 1Z I1 _-_---

I DIMMER I J

VIO/YEL

GRN/ GRY

GRY/RED

22~YEL/GRN

(NOT USED)

INTERIOR LIGHTS SYSTEM

X08

VIO BE, YEL/BLU

1 ___

I I

I)' ---SHIFT-LOCKSOLI j2 I 3

BANDSOLCTRLI)4 S HYDCTRL GNDI

BRN/VIO

WICC M

GRY BRN

OR END SIG L2 I )B i~ 9 BRN/WHT GR RNG SIG L4 10 BLU/ BRAKE PDLPOSIT I (3181as I ) 11 I 12 VEL/GRN 31811) SPORT MODE SIG I ) YEL/WHT MANMODESIG 113 T 14 BLK OUPUTSPEED(- )I 16 NC NCA SPEEDSENSSHOI

S-PROGINDI KICK-DOWNSIGI ASCSIGI AUTO MODE SIG I OILTEMPSIGI

VEL/GRN

GRY/YEL

WHT/GRN/VEL

20 21

VEL/BLU CLR

FAULTOSIOI)26 26

BATTERYVOLTI

M-PROGINDI GNDI 20 I ,29 ' 30 SOLVALICTRLI

TCCSOLCTRLI SOLVAL2CTRLI

I I I I I

RPM - S PEEDSI G j))

_ zJ

2,1, ~ ] TRANSMISSION POSITION INDICATOR LIGHT

SLUIRED1

BLU/REDj

BLU/RED "~

1 BRN

b EXTERIOR

LIGHTS SYSTEM - .. . ..

BRNI Z

BLK

WHT/GRN/VEL

CLR

ELK

GRYISRN

RED

X10

YEL/WHT

BRN

EGSWARNINGLP I

INSTRUMENT CLUSTER

G123

ORG

ORG GRN

BRN

GRY/ RED

BRAKE LIGHT SWITCH

11Y/11N

I~4' 42 OUTPUTSPEED(a)I

BRAKE SWTC. I LIGXT

BRNIVIO

32 33

ON .I I'33

YEL

ELK

BLU

GRRNGSIGLIII3fi 37 GRRNGSIGL3I 138 I9 3

G2D1

OILTEMPSIG(a)I 22 I,23

OlI

W/OCCM

VIOL YEL

1 2

BLU

GRN VEL BLU/BLK

B 10 11

BLU/WHT

ILK VEL

I)43 44

B T-NIA v- _ y

TRANSMISSION CONTROL MODULE (EGS) VEL/BLU

VEL/BLU

GRN N/IE OFF EXTERIOR LIGHTS SYSTEM

3 BRNI BLK

BRN/ BLK

1 G201 8917 0

ATOU AUTO AU

.--1 f M AN

KICK DOWN SWITCH

BLU/VEL

_6 I

IM ELECTRONIC MOBILIZER CONTROLMODULE

CRUISECONTROL MODULE (TEMPOMAT)

BLU/VEL 3 -~ f~ CLOSEDIN ? (E XCEPT REVERSE ~ j 1997 POSITION 31011) AUTOMATIC I

CHIME MODULE

RANGESWSTCH

ELECTRICAL WIRING DIAGRAMS

ELE-103

Transmission Electronics 1996-97 Except M3 (2 of 2) TORQUE CONVERTER CLUTCH SOLENOID VALVE

1 2 3

TRANSMISSION VALVE UNIT

4 BRN

VIO GRV YEL BLU

2 .1

6 7 B

G200

X8421

31-ONLY)

4 _

BRN

OTHERS

BLK

GRV/BLU 45,r------~ JA -PROGIND BLK/BLU 46 IAICCOMPONSIG

RED IVOLTPRESSREG QED/WNT 54{~VOLTAGESUPPLY REO/WHT 55 ~jVOLTAGESUPPLY 56

62 ` I

WHT/GRN/YEL

B3 (, 64 ~,

CLR

65 ~,

BLK

66 (,

BRN/VIO

87 ~~ 68 ( ~ 89rI 70 (I 71 ~

~ 72 73~ I 9 0

ORG GRN

74(1 ""

FLU

75(1 1B

GRN/BLU (1997) WHT/GRN (1996)

76(1

WHT/VIO/YEL (1997) WHT/VIO (19961

78~I

77~I 79~~ 80 C ~ 81 ~~

7 5

WHT/VIC WHT/VEL

(3181x6 " +1811

(32BIONLY)

82 83,1''T 'E' ~ INOT USED

,CAN-LOW VEL Bfi -,CAN-HIGH WHTIYEL 87 i IR.DDATALINK WHTVIO BB ,TXDOATALINK

WHTIVIOIVEL (1997)

ELL BLU

(1998)

(3181, 6 318ti)

BLK/BLU

" I

ELK YEy

, , ,

1-------J TRAMSMISSIONCONTROL MODULE (EGS)

(3181sONLV) (3281 W/ASC)

IA/C COMP CTRL

BO I RPMSPEEOSIG

L~ ICAN-LOW ICANHIGH I

ENGINECONTROL MODULE (DME) 3

CRUISE CONTROL MODULE (TEMPOMAT) 8917 1

COMPRESSOR CONTROL RELAY

ENGINE CONTROL MODULERELAYI

L-_____________I FRONT POWER DISTRIBUTION BOX

SLIP CONTROL MODULE

ELECTRICAL WIRING DIAGRAMS

ELE-104

Transmission Electronics 1998 Except M3 (1 of 2)

HOTATALL TIMES

I L RED

~ ~IeU NCTION

HOTINRUN &START

HOTINRON &START

gUSE F26 1 OA

; I FUSE

L F2S ) T 5A

I_ I ----- -I-----

GRN/ WHIT

HOTINACCV,RUN &START 'FRONT POW ER - I DISTRIBUTION BOX FUSE 146 15A I

X 70017

GRN/ GRV

1 Xla018

VIO/YEL

V10/VEL

(NOT USED)

22 X51 VIO

__-__

I I I

I~1

SHIFT-LOCKSOLI j2

I~ 3

BAND SOL CTRL(

HVDCTRLI-)I GNDi

GR RNG SIG L2

VIO

BRNIBLK

BRN/WHT

YELIGRN

GRV/VEL

WHTIGRN/YEL

VEL/BLU

ASCSIGI MODESIGI AUTO .ODES

OILTEMPS IG( 21 OILTEMPSIG(+JI 22 I~23 I ) 24 FAULT INDEIG I BATTERYVOLTI MPROGINDI -

GNDI

GRRNGSIGL3I 1

1 0

SLUIRED

ETERIOR

iSYSTEM

D 3

NCA

BLK WHT/GRN/YEL

RED VELIWHT

GRV/BRN

BRN/ORG(OR BRN)

ORG

5 X36

BRN

+ G103

BLU/BLK

EGS WARNING LP

L------J INSTRUMENT CLUSTER ORG

GRN

BLU

GRN BRN

ELK 7 BRN/VIO 8 --_ - --,

BLU

CLR

BLK

0 0

1 0

CLR

I ' 35

GRRNGSIGL1I

NCA _

GRVIBRN

TCCSOLCTRLI/32 33

SOLVAL2CTRLI

BLK

1 1

VELIWHT

88 GNDI 1 129 I SOLVAL1CTRLI30 I'31

- ~~

BLU/RED

(1,9 L ON LV)

L7 L2 L3 P q

S-PROGINDI

EGS A4S 310R

BRAKE -- ( LIGHT I~ (SWITCH

BLL/RED YEL/GRN

KICK-DOWN SIGI

VEL 1

12 SPORT MOOESIG I j MAN MODE SIG I 1 3 14 OUPUTSPEEDI)I -

SPEEDSENSSHDI 15 I,16

viol

BRN(79LONLY)

I e

GRRNGSIGI Lb BRAKE PDLPOSIT I 10 ,11

BRNIVIO

GAY VEL/BLU

YEL

BLU/WHT

I)39 RPMSPEEDSIGI

OUTPUTSPEEO(a) I I ,49

I I

BLK

I)42

YEL

BLK

NCA

GRN/GRV

I~ 44

L- - - - - - - J

TRANSMISSION CONTROL MODULE (EGS)

BRNIW HT 0 BLU/

BRN/=LK 0"

GRN/WHT

2 OFF

BRN/I BLK

ELECTRONIC IMMOBILIZER CON7ROLMODULE

BRN/I BLK

EXTERIOR BLUIVEL LIGHTS ~ SYSTEM

BLU/YEL

CLOSI

D IN REVERSE POSITION

CRUISE CONTROL MODULE (TEMPOMAT)

10885 6

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-105

Transmission Electronics 1998 Except M3 (2 of 2)

BRN

BRNN/GRYY

G202

I__~t-

BRAKE LIGHT SWITCH

BRN/GRV

ON-BOARD (COMPUTER I (MULTI-FUNCTION CLOCK)

I I

1 x l VIO GRV VEL BLU 1 .9LONLY) 1 .BL 2.5/2 .8L BRN/GRY 1`

2 .5/2 .8L " I

BLK/BLU 71i LL

1 .9L

VIO

1. ^

4fi

,A/CCOMPONSIG (I 48 IBKSWTESTSIG 49(, 47

YEL/BRN

12 .5/2AL

11 57 58

GRNIBLU BLK WHT/GRN/VEL CLR BLK BRN/VIO

51 (I V~! VOLTAGESUPPLY ED 63 I VOLT PRESS REG T 54 I IVOLTAGESUPPLV RREED/WDIWHHT ~SVOLTAGESUPPLV

5,1

6 7

50 ( I

2 .6I 2 .8L

1 .91

I`-----_-, IA-PROGID I

; ,CRUISE CTRL SIG (I

( 60IPROGVOLTAGE 61 (I e2 (I 63 (I 64 (I 85 (I 66 ( I 67 ( 68 ( I BB ( I 70 ( I 71(I 72( 73 ('

ORG

74 (I

GRN

(I 76 ( I

BLU

77 (, 7B (I 7s ( I

Y-

DATA LINK CONNECTOR

81 ( I

(2 .51-/2 .8L ONLY) BLU 82 (I ~NOTUSED ~I ~INOTUSED BLK

~~ WHT/GRN COMPUTER HT~VE1 DATALINES W~ SYSTEM ~ ' WHT/VIO

CAN HIGH WHT ~IRXDDATALINK WHT/VIO/VEL Be (,T.DDATALINK (1 .91-ONLY)

CLUSTER SYSTEM

ELK

I I

L-I

CRUISECONTROL MODULE (TEMPOMAT)

I I I I I

I 1

! _ I COMPRESSOR CONTROL RELAY

I - QIv m I

ENGINE CONTROL MODULERELAV

FRONT POWER DISTRIBUTION BOX 10885 7

I , I I I I

SHIFT LOCK SLIP CONTROL MODULE

, , I

PANSMISSIONCONTROL MODULE (EGS)

BLK/BINSTRUMENT

85 (I 86 IOAN LOW

A/C

COMP CTRL

ELE-106

ELECTRICAL WIRING DIAGRAMS

Transmission Electronics 1995-97 M3 (1 of 2)

HOTATALL TIMES r~,Ba .JUNCTION I ( POINT

EGS ASS 3102 Ll L2 L3 L4 1 0 1 1

P q

N D 4

1 D

1 1

3 2

1 0

0 0

7 1

7 0

RED

I)1

SHIFT-LOCKGNDI 2 3 SOLVALSCTRL I TCC SOLCTRL 14 5 HYD CTRL (-) I I) I)7

BANIVIO

e GRRNGSIGL2I 19 GRRNGSIGL4 70 BRAKE POL POST

BRN/BLK

S-PROGSIGI 72 13 M-PROGSIG 1 14 OUPUTSPEED(-)I IS SPEEDSENSSHDI TURBINESPOSENSI 16

YEL/GRN

I I I I I I

FUSE F28 --________ SyK .1991Z 32

S-PROGI KICK-DOWN SIGI ABSSIGI

E-PROGI OILTEMPSIGI OIL TEMP SIG(.)( I SPEEDSENSSHDI I

30 I

-F, RED VEL SLU

' "

BLU

WHTIGRN/VEL YEL/BLU

BRN

BLK/RED NCA

SRN

8LU

WHT/GRN/VEL

BLK BLU

BLK/BLU

RED/-T

~JI,G201 IT

GRY/VEL

4 S

7 BRN

- 3,87 J

BLUIRED VEL/BRN

99fi LATE PROD&7997

GRV/BRN

GRVBRN

RED VEL/WNT BRN

BRN

ORG BL.

BLK

VEL

GRN

GRN BRN

WHT/ORN/VEL

WNT/GRN/YEL

WHT

SLUIBLK BLU/WHT

WHT BLK BLK 8RN/GRV

BRN/GRV WHT BLK GRY 1995&1998 EARLVPROD

10 it 12 13

G123

ORG

WHT/BLK

PNK TRANSMISSION POSITION INDICATOR LIGHT

8114 NCA

RED/WHT

VEL/WHT

1 40 I nrmareNSUMeuaiPTIONuI41 I FUELCO 42 I OUTPUTS PEED(1)1 43 ICRANKSHAFTSIGI TURBINESPDSENSI 44

'~ INTERIOR LIGHTS SYSTEM

GRV/ RED

ENGINE I C ONTROL ( MODULE RELAY

BLU/RED

YELIGRN

TRANSMISSION CONTROL MODULE(EGS)

RED g

BRNIWHT

17 i&

GRVIREO

2 BILL IRED

BLUIRED 1998LATE P1997ROD&

I) SOLVALICTRLI 30 31 SOLVAL,CTRLI 32 SOLVAL3CTRLI SOLVAL2CTRLI 33 34 GNOI 35 DKT-INTERFACE( 36 GRRNGSIGL1I 137 GRRNGSIGL3 138 I13g

BRAKE LIGHT I SWITCH

BAN VIO

RED

FAULTINDSIGI)225 26 BATTERVVOLTI 27 M PROG 28 ONOI

X19018

VIO/YEL 1

RED

CLR

20 21

FRONTPOWER DISTRIBUTION BOX

viol YELj

PNK

)11

FUSE F48 1AI ____ 1 _

FUSE F26 10A -rrr-

DIMMER

HOTINRUN HOTINRUN HOTINACCV,RUN &START &START & START r_______,______________

G RV

NCA

14 15 7B 17 1S 19 2D 21 22 23

LL, _ III NCA

GRN/WHT

H 996 LATE PROD & 1997 EXTERIOR

SRN/I BLK ( KICK DOWN SWITCH

PROGRAMSWITCH

NCAI 1

89231

I I

J '

BRN( BLK

I I

ELECTRONIC IMMOBILIZER CONTROLMODULE

mI I I I

I I

___ I CRUISECONTROL MODULE (TEMPOMAT)

~, I

Xt4 (NOTUSED)

I I I

CHIME MODULE

CLOSEDIN REVERSE POSITION AUTOMATIC TRANSMISSION RANGESWITCH

ELECTRICAL WIRING DIAGRAMS

ELE-107

Transmission Electronics

1995-97 M3 (2 of 2)

VALVEDIID

III

VALVEYID

III

VALV13 ID

VSOL ALVEOID

III

VALVE

SID

TRANSMISSION VALVEUNIT

HYDRAULIC PRESSURE REGULATOR

YEL/BLU

r------ ~

11CI E-PROGSIG (~

411

47(1 46

I I

49 (I 5D 51

REO/WHT

BRN

-A

VIO VIO RED/WHT

I SHIFT-LOCKSOL 1 VOLTAGESUPPLY

5534 ~I

iVOLTAGE SUPPLY

55C

1998 LATE PROD &1997

56( 1 YELBRN

57 56

IORUISECTRLSIG

(I s9 (1 GRN/BLU

60 ~IPROD VOLT 61 62

WHT GRN YEL

( 52,1

(I (1

63 (1

BLK/BLU

64 (I 65

_BLK/RED

fib

( 67 (1

YEL/BRN

6e (1

GRV/BRN

s9 ( 1 70 ( I 716 71 73~

ORG

(1 75(1 76(1

BLK

15 18

YEL GRN

77(I 78(1 79 ( 1

WHT/GRN/YEL WHT

WNT/BLK

ILK

BRN/GRV

BLK 85 (1 ~ICAN LOW

( 1 CAN-HIGH

1995 k 1998 EARLVPROD

e7(~

WNT/VIO 88

I 1 I

IT%DDATALINK 1 L_ _ -----J TRANSMISSION CONTROL MODULE (EGS)

196LATEPROD &1 .97 INSTRUMENT CLUSTER SYSTEM

WHT/BLK

-I

1 I I

;

ENGINE CONTROL MODULE (DME) 8923 2

JUMPERPLUG

~ JUMPERPLUS 14

GRV

( 81 (1

I I

I I I

ON-BOARD COMPUTER I

h o

D I

L--_-1

INSTRUMENT CLUSTER

SHIFTLOCK

SLIP CONTROL MODULE

ELECTRICAL WIRING DIAGRAMS

ELE-108

Transmission Electronics 1998 M3 (1 of 2)

EGSA5S310Z Li L2 L3 L4 P

D 4

0 0

0 1

1 1

HOTATALL TIMES ,B~ I M JUNCTION ( POINT

I-

D (

HOTINRUN &START

FUSE F2fi

FUSE F28

I 12

HOTINACCY,RUN &START ___--

__A_----tfiY-A---__----

32 1 X90 78 VIO/I YEL"

x1001-Z

GRN( WHT

FRONTPOWER I DISTRIBUTION BOX

FUSE F46

GRN/ DRY

VIO/YELj 1

RED

117 I_`_ 1.J "

BRAKELIGHT SWITCH

BLUIRE2DY I

CLR/WHT RED YELIBLU

I) 1 I 2

SHIFT-LOCK ONO

BRN/VI0 PNK

SOLVALSCTRLI 'C'S 0 CTRLI 4 HYDCTRL 1-) 1 5

OR RNGSIGL21

C=R/WHT RED

BLU/RED

2TTT

)11

S-PROG SIG( 12 M-PROG SIG 113YEL/I=HT 14 BF . OUPUTSPEED(15 NCA SPEEDSENSSHD 1fi BLU TURBINESPDSENSI 17 YEL/GRN S-PROGI 18 GRYIYEL KICK-DOWNSIGI 19 WHT/GRN/YEL 20 YELIBLU E-PROGI 121 BLKIBLU OIL TEMP S IG 22 BLK/RED OILTEMPSIG()I NCA SPEEDSENSSHDI

RED/WHT

)I I I

FAULTINDSIGI)21 26 BATTERY VOLTI 27 M-PROG 28 GNDI I )29

SOLVAL4CTRL

REC/WHT B RN BLU

WHT/GRN/YEL "

< BLKIBLU DLK/RED VEL/BRN

GRY/BRN

RED YEL/WHT BRNIORG

BRN

GAG

ORG

I 31

BLK

YEL

GRN

SOLVAL3CTRLI SOLVAL2CTRLI

8 7 8

g 10 11 12 13

~I ,IG103

SOLVAL1CTRLI

7.--t ENGINE CONTROL MODULE RELAY ~.B7

3 4

RED(

I g BRNIWHT GRRNGSIGL41~ BRAKEPDLPOSITI

1 2

14 15 16 17

o~~~m H

mmmmmmm N~MMNNNNE

1®1"IIII

GRN/WHT

2 0

mfl

BRN/ BLK

IM ELECTRONIC MOBILIZER CONTROLMODULE

10885 8

~ I

__5,I_ 7AI

EXTERIOR I LIGHTS !SYSTEM

I I

CRUISECONTROL MODULE (TEMPOMAT)

R -

CLOSEDIN REVERSE POSITION AUTOMATIC TRANSMISSION RANGESWITCH

ELECTRICAL WIRING DIAGRAMS Transmission

ELE-109

Electronics

1998 M3 (2 of 2)

VALVE2 VALVE3 VALVE 07 1D

VALVE4 ID

VALVE5ID

TRANSMISSION VALVEUNIT

YELIBLU

{I E-PROG SIG (I (I

46 BRNIGRY

37 4 L(IEKSWTEST SIa 49

WIG

VIO

RED/WHT

BRN

BLU

GRN/BLU

(I (I (I 64 ( I 6s ( I 63

I I I 7o ( I 71( I I 67 ( 88 ( 89 (

GRY/BRN

_ORD =EL

16 19

74 (I 75

BLK

60, LIPROGVOLT 61 62

VEL/BRN

1CRUIEECTRLSIG

BLK/RED

57( 58 59 (I

BLKIBLU

BHIET-LOCKSOL

58 VELB/ RN

WHTIGRNIYEL

I I

VOL7AGESUPPLY 54 { I VOL7AGESUPPLV 55 (

(I I I

76 (

GRN

77 ( 7B

(I 79d eo I 81 (( I BLU 82 I

WHT DRY

JUMPERPLUG L 11~I IJUMPERPLUG ELK 84 (

COMPUTER DATA LINES ~~ SYSTEM

DATA LINK CONNECTOR

W HTIVIO/VEL

85 ,!CAN-LOW YEL 86, --RICAN-HIGH 87 WHT/VIO/VEL

88 (

ITxDDATALINK TRANSMISSION CONTROL MODULE (EGS)

WHTIVIO/VEL GRN/BLU

BRN

I I

BRN/GR

BRN

G202

BRAKE LIGHT SWITCH

BRN/GRY

I 1 I 1 I

~ " o

I I I I I

L- - - - J ENS NECONTROL MODULE (DME) 10885 9

I I- ---I

INSTRUMENT CLUSTER

1111T LOCK

I I

CONTROL I SLIP MODULE I

I I

ION-BOARD COMPUTER IMULTI-FUNCTION (CLOCK)

ELE-110

ELECTRICAL WIRING DIAGRAMS

Shift Interlock HOT AT ALL TIMES

~:PUUNNTION 16

HOT IN RUN AND START 1FRONTPOWER III FUSE iDISTRIBUTIONBOX

HOT INACCY.RUNANDSTART

-----------

ri L

FUSE 15A

__-_______ 3W`(XInB1e

1 ,8

BRN/BLK

2 1

STARTER RELAY

I2SBRN/BLK

BRNII

BLU/WHT6

/ ~I' G123

I I I

Z (318) 65 (325) 81

ENGINE DRIVE ( CONTROL I RANGE

l-___ TRANSMISSION CONTROL MODULE

P/N

(MODULE

-I

83379

HOTATALLTIMES

VIO

: j" GROUND

BRN

(GEAR RANGE SIGNAL LI I

123

~GEARRANGE SIGNAL L2 BATTERY VOLTAGE

HOT IN RUN AND START -7F DINT POWER FUSE DISTRIBUTION BOX ? F28

B. JUNCTION POINT

ISHIFTLOCK11 I SOLENOID : CONTROL( e (GEARRANGElI I SIGNALL31

: :33 (GEARRANGE I , I SIGNAL L4IT SHIFTLOCK i35 SOLENOID I GROUND(

GROUND~36

BLU/BLK

RED BRN/WHT

gRN/VIO 2 NCA

BRN/ORG

83648

NCA -

SHIFT-LOCK

:BRAKELIGHT I39 BLU/RED SIGNAL : TRANSMISSION CONTROL MODULE

---- r --

BLU/WHT

26 BR

128

R. }PI

I I

71 X22CRUISE

1 CONTROL

1(MODULE

O m A C123

N R D~

BRNIWHT B :

BRAKEPEDAL!39 BLU/RED POSITION

GEAR RANGE 33 BRN/WHT SIGNAL L4 SHIFT LOCK 36 BRN/VIO SOLENOID GROUND BRN/ORG . RNIORG GROUND13 B~

3~~ 2

ERIN 119~

BATTERY 1,28 RED VOLTAGE( I

D "

1 I

BLU/WHT

GEAR RANGE 123 BLU/BLK SIGNAL L7 GEAR RANGE 1 ,26BRN/BLK SIGNALL21

r I

CONTROL MODULE

VIO

BLUIBLK 4

GROUND

BRAKE LIGHT SWITCH (

X18817

¢ O\'

> O

SHIFT LOCKI I SOLENOID1 SOLENOID CONTROL( GEARRANGEI S SIGNALL3

-"-. y 2

. I

I I I

AUTOMATIC TRANSMISSION RANGE SWITCH

ELECTRICAL WIRING DIAGRAMS

ELE-111

Shift Interlock HOTAT HOTINRUN, ALLTIMES ACCANDSTART r Ba F28FUSE JUNCTION I F4 6 E POINT 15A _

-HOTINRUN ANDSTART

1FRONTPOWER IDIfiTRIBUTIONBOX

xjDDu

,BRAKE LIGHT I SWITCH

2T wI

SHIFTLO SOLENOII 1)2 GROUND, I GEAR RANGE 6 I SIGNALL2

BR N/VIO

1998

N/BLK

Except 3181, 318ti

GEARRANGEI 9 B N/WHT SIGNAL L4 I ~

BRAKEPEDAL1 ,10 BLU/RED POSITION I'

BATTERY 1,2B RED VOLTAGE,' BRN/ORG GROUND 1 )28

GROUND

: ) 34 BRN

GEARRANGE I~36 BLU/BLK SIGNALL1 1 I GEARRANGE~)37 BLU/WH I SIGNALLII~ I SHIFTLOCKI 52 VIO I SOLENOID,` CONTROL I~ TRANSMISSION CONTROL MODULE

SHIFT-LOCK

1 .1

AUTOMATIC TRANSMISSION RANGESWI7CH

lzl

'A-G103

104722

NOTAT ALLTIMES

JUNCTION POINT

HOTINRUN HOTINRUN ACCANDSTART ANDSTART r -----------1FRONTPOWER FUSE DISTRIBUTION BOX I F28E ,5A 5A 32YXIS003B - ,6 X70017

BLU/BLK 4~ , J

2y ° mI _

BRN/BLK 7

BRN/VIO

GEAR RANGE 10 SIGNALL4I

1 I

P I N

D " 3 " 2"

GROUND I)L GEARRANGE I SIGNAL L2,

I 1

SHIFTLOCKI 2 SOLENOID GROUND,

, BRAKE LIGHT , SWITCH

BRN/BLK

BLU/WHT 6

BRN/WHT

SRAKEPEDALI 10 BLU/RED POSITION I BATTERY 1 )26 RED VOLT GEI 28 B GROUND 1 34 BRN GROUND, GEARRANGE I 06 BLU/BLK SIGNALL1 GEARRANGEI)37 BLU/WHT SIGNALL3 I SHIFTLOCK 52 VIO SOLENOID I CONTRO=I TRANSMISSION CONTROLMODULE

104719

BRN

,~i, G103

' I' BRN/WHT B ~ I

21 AUTOMATIC TRANSMISSION RANGE SWITCH

1998 3181, 318ti

ELECTRICAL WIRING DIAGRAMS

ELE-112

Cruise Control

1992-93

HOTINACC,RUNANDSTART HOTINRUNANDSTART -_---_---_-~ . .-----

FRONT ( .POWER

" CHECKCONTROL MODULE

"" TRANS ISSIONCONTROL MODULE

VIO/YEL

I JR* _

VIO/YEL

W/OCCM

AUTOMATIC I TRANSMISSION (RANGE I SWITCH

WICCM

1,k

BRAKE LIGHT SWITCH

YEL/VIO CRUISE CONTROL SWITCH

BLKIGRN

1J"

`W/EGS "" I

BRAKE I LIGHT I SWITCH

W/O-

"" I

CLUTCH SWITCH

YEL/VIO

YELIWHT

15 16

BLK/W HT BRN/ORG BLU/RED

BLK/BRN

BLU/WHT

BLU/GRY

SLU/GRN

23 2<

CRUISE CONTROL MODULE

CRUISE CO NTROLACTUATOR

BLU/BLK

I I

VEHICLE SPEED SENSOR

I I

INSTRUMENT CLUSTER

67095

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-113

Cruise Control

1994 & 1995 Early Production Except 318ti HOTINRUNANDSTART

I L

HOTINACCY,RUNANDSTART

FUSE ,FRONTPOWER IDISTRIBUTIONBOX F46

FUSE F26

-A6 -J

viol

GRNJ GRY

Y EL

VIO/YEL

~1 . . 2. 3

W/OCCM

I AUTOMATIC I TRANSMISSION RANGE I SWITCH I

[

BRAKE LIGHT SWITCH

YEL/VIO

BLK/GRN

W/0 CM

BRAKE

I LIGHT

I SWITCH

CRUISE CONTROL SWITCH

BLU/RED

EXTERIORLIGHTS SYSTEM

CLUTCH SWITCH

BLK/BLU

12 WlEGS

13 14

W/OEGS

YELIWHT

1S 16

BLKIWHT

BRN/ORG

BLU/RED

BLK/BRN

BLU/WHT

BLU/GRY

BLU/GRN

CRUISECONTROL ACTUATOR

BLU/BLK

VIO/YEL

CRUISE CONTROL MODULE

I 1

G203 63528

I VEHICLE I I SPEED I I SENSOR

IN STRUMENTCLUSTER

ELE-114

ELECTRICAL WIRING DIAGRAMS

Cruise Control

1995 Late Production & 1996-97 Except 318ti HOT IN RUN AND START

)

HOTINACCY,RUNANDSTART FUSE ,PRONTPOWER DISTRIBUTION BOX F46

USE F28

LI-A____________I-B! J

viol

IRNI DRY

VEL

V101YEL

. ~2 3

W/ C CM

WW/OCCM

AUTOMATIC ' TRANSMISSION RANGE SWITCH

YELIVIO

BRN/ORG (OR BLU/BRN

BRAKE LIGHT SWITCH

!Jll _

BRAKE I LIGHT I SWITCH

CRUISE CONTROL SWITCH

BLK/GRN

TRANSMISSION CONTROL MODULE

BRN/BLK

I 2fI

6 7

YELIBRN

BLK

BLU/GRV

SLKIWHT

Q x

IMEMIN

YEL/WHT

BLU/BRN

16 17

WHT/VIO

BLU/GRN

COMPUTER DATA LINES SYSTEM

19 26

BLUIBLK

22 23

RED/BRN

BLU/WHT

25 28 CRUISECONTROL MODULE

V10/YEL

LL O

CRUISE CONTROL ACTUATOR

g-CLUTCH SWITCH

BRN /GRG 11

G203

BRN/ORG

VEHICLE SPEED SENSOR

ENGINE SPEED

INSTRUMENT CLUSTER Besafi

I I

ELECTRICAL WIRING DIAGRAMS

ELE-115

Cruise Control 1995-97 318ti

HOT IN RUN AND START

HOT IN ACC, RUN AND START

CRUISE CONTROL SWITCH

W/EGS

WIOEGS

CLUTCH SWITCH

BLK/WHT

BLK/BLU

111~1~~~~ 1111~1~~

WHT/VIO 18

BLU/GRN 1997 ONLY

19 20

BLU/BLK

BRNIORG

CRUISE CONTROLACTUATOR

22 23

RED/BRN

BLUIWHT

VIO/YEL

CRUISE CONTROLMODULE

82783

COMP UTER DATA LINES

ENGINE CONTROLS SYSTEM

I I

INSTRUMENT ENGINE VEHICLE ( CLUSTER SPEED SPEED I INPUT SENSOR - - - ----

0203

ELE-116

ELECTRICAL WIRING DIAGRAMS

Cruise Control 1998

HOTINACCY, RUNANDSTART FRONTPOWER USE FUSE I DISTRIBUTION BOX F46 F28 6A _-_________________ Z15A_I

HOTINRUN ANDSTAR_T

V[ 32Y 011 YEL(

Viol YEL

I P I R" I N I I_

viol YEL

DECELERATE/ SET

BRN/ BLKI

TRANSMISSIN( O BRN/BLK " ~~CONTROLS 1 I SYSTEM

BR BLKI

YELNIO

BRNIORG (OR BLUIBRN

YELIBRN

BLK

BLUIGRY

BLKM'HT~

BLK/BLU

BLK/BRN 12

BRNIOPG

144

YELIWHT

RESUME

OFF

1NORMAL

ml NCAT

INCA),

NCAT

BLU/ WHT

BLU( GRIN

BLU( GRY

BLU/ BLK

W/ OCCM

W/CCM

Viol~ YEL

VIOlI YE

BRAKE LIGHT SWITCH

N CAT

BRNIBLK

CRUISE CONTROL SWITCH

ACCCELERATE/ SET

NORMAL

BLK/GRN

V'O' YEL

NCA_

(AUTOMATIC (TRANSMISSION 1 RANGE . ~ 2 ( SWITCH I 3 I _~

.J1/i4L

BRAKE (LIGHT I SWITCH

yyy'((( BLUII RED I

BLU/~ RED( I BLU/( RED

EXTERIOR BLUlRED " ~ LIGHTS SYSTEM BLU/I RED

TRANSMISSION CONTROL MODULE YEL/BRN

BLKIBLU

BLKIBRN

67 .11

15 16

WHTNIO

BLU/GRN

BLU/BLK

BRNIORG

COMPUTER 1'DATALINES SYSTEM CRUISE ONTROL ACTUATOR

22 23

REDIBRN

BLUIWHT

25 26

BLKI WHT VIOIYEL BRN/I OR G

CRUISECONTROL MODULE

BLKI I WHT(

BLK

2,L

TACH OUT

ENGINE SPEED

INSTRUMENTCLUSTER 104520

B RN( ORG

I I

1 BRN/( ORG 1 G201 1 G 203 (31811) (318,323, 328, M3)

ELECTRICAL WIRING DIAGRAMS

ELE-117

ABS

1992-94 w/o Traction Control HOTINACCY. RUNAN.lD~START

HOTAT HOTINRUN ALLTIMES ANDSTART -----------E----------------SE F3B F2 -

FIFUSE F413 L

3-'4-------------- .L3-A------- .----------

HOT AT ALLTIMES z UFUSE

20 RED/ BLU

GRN/BLU/I VEL

RED/ BLU

B RUN]

-0A -------__--

-A ---

2 GRN/BLU/I VEL

HOT IN RUN ANDSTART ----------~ FUS F27 E

FRON DISTRIBUTION BOX

-'A

14 GRNI VIO

GRY/BLK/ YEL

RED/BLUI 8 YEL

ABSRELAV

ILI 5

GRNI VIO

BN " ~ + G202

GRY/BLK/VEL

A BS WARN IND

I I I

INSTRUMENT CLUSTER BLU/RED 32 PUMPMTRRLYCTRL

RED/GRN/VEL

))

52 1 53 7 33

ABSWARNINGLPCTRL VOLT SUPPLY, TERMINAL I9 OPERATING VOLT

) 34

ASS RELAY CTRL PUMPM1RSEN551GNAL PUMP MTRSENSSHIELD

LFNTINLETVLVCTRL

RFNTINLETV LVCTRL

RFNTOUTLET VLVCTRL

REARAXLEOUTVLVCTRL REARAXLE INLET VLVCTRL VOLT MON, HYDRAULICS

GRN/BLU/YEL RED/BLU/VEL FNfBLX

BLU

NCA

G202

BRN/WHT/VEL

BRN/GRN

FLSPOSENSGROUND1

FL SPEED SENS SIGNAL

FRSPDSENSGROUNO PEDALTRAVELSENS PEDALTRAVELSENS SEN.

BRNIGRN/VEL

BRN/WHT

BRN/BLU

RED/BRN/VEL

BAN

NCA

RED

NCA

BLUIGRY YEL

YEL

NCA

RLSPEED SENSSIGNAL 1 )46

WHT

SIGNAL

RR SPEED SENS SIGNAL

RLSPDSENSGROUNOI)

RXD DIAG DATA LINK TXD DIAL DATA LINK RRSPDSENSGROUND

N CA REO/BLU/YEL

B 3 , l

BRNIW HT/VEL

BRNIGRN

BRN/RED

BRNIGRN/VEL

II II

PUMP MOTOR SENSOR FRONT LEFT INLETVALVE

RIGHTFRONT INLETVALVE

LEFTFRONT OUTLETVALVE

RIGHTFRONT OUTLETVALVE

REAR AXLE .TLETVALVE

REAR AXLE INLETVALVE

I- G203

NCA

RED

NCA

YEL

NA L CA WHT/VEL "

15,

WHT/VIO 2 0

CONNECTOR BLUIBLK

BLU/GRY

SLIP CONTROL MODULE (ABS) ABSBRAKEPEDAL TRAVELSENSOR 98445

BLU

ABS HYDRAULIC UNIT

WHTIVI O NCA

RED/BRN/YEL12

WHTIYEL 42

BRN/WHT 10 BRN/BLU 11

41BLU/BLK 47

FR SPEED

SPIN

BRN/RED

GROUND,CTRLMODI~ GROUND,CTRLMOD

"Ip

LFNTOUTLETVLVCTRL

LEFT FRONT ABS SPEED SENSOR

RIGHT FRONT ABS SPE I BEN

LEFT REAR ABS SPEED SENSOR

ELECTRICAL WIRING DIAGRAMS

ELE-119

ABS/AST

1995-97 318ti & 1997 3181, 3181C & 318is w/Traction Control HOTINACCV, RUNAN..~~~OCCCSTART

HOTAT ALLT..777 ICCCMES -_-_--------'

FUSE

HOT IN RUN ANDSTART --~`FUSE

----_-_-

FUSE

- - -

HOTAT ALLTIMES

HOTINRUN AND~~ S. .TART T

1S I

VIGII VEL

RED/) GRN

VIO/I VEL

RED/ GRNI

rIT

20Y REms1-.G1

GRN/I EL U/ VEL

GRN/ FLU/ 1 VEL

GRN/U/

GRN/VIO~ 23 ABS PUMP MOTOR RELAY

(

INSTRUMENT I CLUSTER

ASS

GRN/~ RED

VEL

14~I' GRN/VIO/

REDJBLU~ 8

INTERIOR LIGHTS SYSTEM

ON BOX

ORS RTBU

F27 E F7-E-----------

ABC IND

2 BRAKE LIGHT

ABC SWITCH

1 SWITCH

___

EXTERIOR LIGHTS SYSTEM RED/GRN/YEL

BLU/RED /

G202

.FN 1G203

DATA LINK CONNECTOR ~ 2D "

TXDDIAG BRAKELIGHTSWITCH VOLT SUPPLY, VOLTSUPPLV,FUSE FUSE 38 3'

VOLTSUPPLV,F USE21 ABC SWITCH ABS PUMP MOTOR RELAY ABSSI GN AL

WHTIVIO

BLU/RED

RED/GRN

29 13

RED/GRN GRN/BLU/VEL

BLU/VIO

BRN/BLK

RED/BLU

1 , 42

ABS PUMP MOTOR RELAY ASS SIGNAL INSTRCLUSTER ASCLAMP

BLU/BRN BRN

RED/BLU/VEL

RED/BLUIYEL

BRN/WHT/YEL

BRN/RED

39 37

BRN/GRN BRN/GRN/VEL

BRNIWHT

BRN/BLU

BRN/BLK/YEL

i 34 31 j 25 2

BRN/GRN/VEL

ABS HYDRAULIC UNI ASS SIGNAL LEFT FRONT INLET VALVE

)

LEFTFRONTOUTLETVALVE RIG NTFRONTINLETVALVE

LEFT REAR OUTLET VALVE LEFTREARINLET V ALVE RIGHTREAROUTLETVALVE RIG HTREARINLETVALVE SEPERATORVALVE RRSPDSENSGND RR SPEED SENSOR ABS RFSPOSENSGNO RF SPEED SENSOR ABS LRSPDSENSGND LR SPEED SENSOR ABS

CANLOW

VEL/BRN

318U

VELIBRN

(3181,3181C,3181s)

YEL

31611

VEL/BLK

( 3181 .3181C .3181s)

BRN

3 18U

BLU

BRN

BRN/RED BRN

BRN/GRN

BRN/GRN/VEL

II II

6RN ERN VEL BFN

" "

LEFT FRONT SO-NOIDVALVE

SOLENORDVALVE

RIGHT FRONT II SOLENOID VALVE

II L IT FEAR

SOLENOIDVALVE

DSIIii

CIE

1 87

WHT/ FN -BEN 1 G203

G202

BRNIRED

ZI 2I

SEE30R

Z IF

IFRONT

88574

LEFTFRONT SOLENOIOVALVE

RE SLEOLFTE NOAR IOVALVE

RIGHTREAR SOLENOIDVALVE

SEPARATING VALVE

ABS HYDRAULIC UNIT

SLIP CONTROLMODULLE LABS) ENGINE CONTROLS SYSTEM

BRN/RED

BRNIBLU/VEL

41 17

BRN/BLU

BRN/BLUIYEL

(3181,3181C,3181s)

GROUND

RED/BLU

M11JII

BRN/GRY/VEL 24

(318L3181C .3101s) 31811

)19

BRN/BLK/VEL 25

YEL

GROUND

CANHIGH

BRN VEL/BLK

) 26 9

BRN/WHT 19

LFSPDSENSGND AB LF SPEED SENSORS RRSPEED SIGNAL OME

REO/BLU/VEL BRN/WHT/VEL

GRY/BLKIYEL

GROUND

RIGHT FRONT OUTLET VALVE

RED/GRN/VEL

BRN

IIISEN90R

ONT

SENSOR

FEAR SENSOP

ELE-120

ELECTRICAL WIRING DIAGRAMS

ABS/AST

1994-95 3251, 325iC & 325is, 1996-97 3281, 3281C & 328is, 1995-97 M3 w/ Traction Control (1 of 2) HOT IN ACCY, HOTAT HOT IN RUN HOTAT RUNANDSTART ALLTIMES ANDSTART ALLTIMES ----------------------------------------S -I USE USE DISTRIBUTION BOX F46 US /FU EL / F 0 I 30A_I =5=___--_--___--Till .-___-_-__-_--______-___- _ .J'SA-_-

VIOI VEL

GRN/BLUIVEL

1994 32510 N LY

GRNIBLU/ ~VEL

RED/ BLU

GRY/BLK/ YEL 9 ABS RELAY

VIO/YEL

ABSPUMPMTRRLY

BATTERYVOLT BATTERYVOLT ,SUPPLY LREARSOLVLVSIG

BRWGRV

2 RED/BLU/YEL 16 RED/BLU/YEL 33

REOIBLUIYEL

RRN/BLU

REDIBLGI VEL

GRV/BLKIYEL

G202

RED/BLU/YEL RED/BLUIVEL RED/BLU/YEL BRNIBLU . RED/GRN/YEL

4 5

SIGNAL EML-SIGNAL

6 18

-S INFLUENCE LPEAS SOLVLVSIG ADS STEP MOTOR ADS STEP MOTOR ABSLPCTRL IGNSIG SOLVLV

ABSPWRPROTECT RLY PUMP MTRSENSSIGNAL RTFNTSOLVLVSIG LREAR SOLVLVSIG LFNTSOLVLVSIG SPDSIG ASC THROT FLAP POT ASCTHROTFLAPPOT ABC LP CTRL FITFNTSOLVLVBIG ASCTHROTFLAPPOT PUMPMTRSENSSHIELD IDLESPDSIG THROTFLAPPOSTH ASCSWSIG LFNTSOLVLVSIG ,SUPPLY L REAR SOL VLV SIG

6 BRN/I BLK

WHTIGRN

WNT/GRN WIT/REDVEL

WHTIRED/VEL WHT/GRN/VEL SRN/-T

SENSGND

BLKISRN/VEL

BRNIWHT BLK/BRNIYEL

BLK/GRN/VEL

8LK/GRN/YEL

GRV/BLK/VEL

GRN/BLU/VEL

BRNIBLU/VEL

13 49

BRN/BLK BLU

BRNIGRNIYEL

BRN/GRV/VEL

FNIWHTIYEL

BRN/BLU/YEL

RFSPEEDSENSSIGNAL

SIGNALABSTRAVELSENSI) SENSGNDI TXDSIG RXOSIG LRSPEEOSENSSIGNAL ASST RAVELS EN SSIG GROUND GROUND,MODULE GROUND

88685

18 19

HT/RED

WHTIBLU

BLUISRN

8'URN /B

22 23

BRN/GRN WHT/BRN

BRN/G RN

NCA

WNTIGRY

WHTIGRY/VEL

BLU/VIO

54 51

BRN/RED

BLK WHT/RED WHT/BLU

WHT/GRV WHT/GRV/YEL BLU/VIO BRN/RED

RED/BLU

RED OR

NCA REDORYEL

NCA

iEL ~

YELEL 45 14 2~9

20 21 22 23 24 25 pfi 27 28 29

BRN/BLK/VEL

GRN

NCA

NCA -

NCA

YEL

NOA

LEFT FRONT ABS SPEED ,4 1 SENSOR

RIGHT FRONT ABS SPEED SENSOR

O BLU/LUGRY CA

WHTIVIO j 7 WHT/VEL j 8 W46 j 31 BLU/BLK ! BRN 1 BRN j 3 j 19 BRN

WHT/VIO 20 DATA LINK W-1-1-l61 CONNECTOR

-1 -

BLUI BILK 1

SLIP CONTROL MODULE (ADS)

BRN/WHT/VEL

BRN/BLK/VEL

)

BRN/GRV/VEL

NCA

BRNIGRNIYEL

WHTIGRN

BLU

BLK

RRSPEEDSENSSIGNAL

SENSGND SENS GNO

20 21

NCA

LFSPEED SENSSIGNAL SIGNAL

8 9

WHT'GRN/YEL

G203

BLU/ GRY

ABSBRAKEPEDAL TRAVEL SENSOR

RIGHT REAR ASS SPEED SENSOR

ELECTRICAL WIRING DIAGRAMS

ELE-121

ABS/AST

1994-95 3251, 32511C & 3251s, 1996-97 3281, 328iC & 328is, 1995-97 M3 w/ Traction Control (2 of 2) HOTINRUNANDSTART

FUSE ,FRONT POWER

I F27 I DISTRIBUTION BOX L 5-_J 14

GRN/ VIO GRN/BLU/VEL

BLKIGRN/YEL AUXILIARY THROTTLE POSITION MOTOR

M I

GRY/BLK/YEL

RED/BLU/YEL

RED/BLUIYEL BRNIBLU

RED/GRN/YEL

WHTIGRN

1S 11 12 13

BLU/BRN

-7-1 ABCDIODE

REDIBLUIYEL

5 B

ELK/BRN/YEL

LYJ RED/BLU/YEL

WHT/RED/YEL WHT/GRNIYEL

GRN/BLUIYEL

BRN/WHT BLKIBRN/YEL BLK/GRN/YEL

BLU/VIO INTERIORLIGHTS SYSTEM

BRN/BLU/YEL

15 18 17 18 19 20 21 22 23 24 25 2B 27 28 2B

BLU

GRO=C

G203+

BRN/GRNIYEL BRNIGRYIYEL

ASCSWITCH

BRN/WHT/YEL BLK WHT/RED WHT/BLU

RED/GRN/YEL

BLU/BRN

BRNIGRN

5-00-1

MIMMEME

-T/13F . NCA WHT/GRY WHT/GRNIYEL

G202

BLU/VIO BRN/RED

iim1111

BRNIBLK/YEL

-Ip SPIN . T

MEMO

-T

BLU 22

(

NCA 21

RED/BLU/YEL

PUMP MOTOR

}II SENSOR

LEFTFFONT INLETVALVE

BRN/WHT/YEL

LEFTFRONT

II OUTLETVALVE

SRN/RED

WHT/RED WHT/BLU

WHT/BRN

RIGHT FRONT INLET VALVE

BRN/GRN

AU%'LIARYTHROTTLE POSITION SENSOR

BRNIGRN/YEL

RIGHTFRONT

II OUTLETVALVE

19 (1996-97328' .M3)

I 6 WHT/ I }55 5RI1011 I ITRANSMISSION

BRN/WNT 19 -1994-95

CONTROL MODULE (EGS)

I I

i 47 1 62

I ;82

h83

WHTIGRYIYEL (ORBRNIORG)

BRN/BLU 18

BRN/BLK/YEL 2

WHT/GRY/YEL (ORBRN/ORG)

BL WHT/ WHT/GRY WHT/GRN

ENGINECONTROL MODULE (OME)

BRNIGRY/YEL 2 REOI BLU/VEL 17 BRN/BLU/VEL 1 6

LEFTREAR OUTLETVALVE

LEFTREAR INLETVALVE FIGHT-AR ~11 OUTLETVALVE J RIOHTREAR (I INLET VALVE

II SEPARATOR VALVE

ABS HYDRAULIC UNIT

88567

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-122

ABS/AST

1996 318i, 318iC & 3181s w/Traction Control

ri L

HOT AT ALL TIMES HOTINACCY,RUNAND START FUSE 6----------',-A

isTT

2o RED/~ BLU

REO// GRN

VIO/I Y EL

HOT IN RUN AND START

HOTATALLTIMES USE

FUSE F38----------30A

P10 -----------------30A

FUSE FRONTPOWER F2- J DISTRIBUTIONBOX 5A

FUSE 121 ---15A

GRNIBLU~ YEL

VI / IO 14

GRN

ENGINE CONTROLS SYSTEM

GRNIBLU/YEL 15 9

YEL

WHTfGRY/=EL

BL/RE=

18 SPIN 6 RED/GRN 29

R~ ED/

GRN/BLU/YEL

, 42

G~ R

/BLKIVEL

S 1 RED/GRN/YEL 1212 BLU/BRN 14

RNIBLU/VEL } 31 B 27

RED

/BLU .

RED/BLU/YEL

BRN/WHT/YEL

BRNIRED

./RED BR

BRN/GRN

SENIOR

BRN/WHT

BRN

RNIBLU

BRN

RED/B~

REO/BLU/YEL

LU/VEL

II LEFTFRONT

SOLENOIDVALVE

BRN/WHT/YEL

BRN/GRN/YEL

LEFTFRONT SOLENOID VALVE

RIGHTFRONT SOLENOID VALVE

RIGHT FRONT SOLENOID VALVE LEFTREAP SOLENOIDVALVE

II LEFTIEAR

SOLENOIDVALVE

II RIGHTREAR

SOLENOIDVALVE

BLK/EL

BRN /BLK

0RNIGRY/YEL

BRN/GRY/YEL 24 ,

RIGHT REAR SOLENOIDVALVE

PBS HYDRAULIC UNIT

BRN/RED

SRN

YEL

BRN WHT/VIO

}3 BL 24 FRN2 YEL/BLK

23YEL/BRN ~ 19 BB RN 41 BRN SLIP CONTROL MODULE (ABS) 89149

WHT/VIO

20, DATALINK CONNECTOR

SRN/RED

NCA

SON

NCA

VEL.~

NCA

LEFT FRONT ABS SPEED SENSOR

RIGHT FRONT ASS SPEED SENSOR

ELECTRICAL WIRING DIAGRAMS

ELE-123

ABS/AST 1998 318i, 318ti w/Traction Control 3

HOTINACCY, HOTAT RUN AND START ALLTIMES -----------F USE FUSE F4fi F38 15A 30A ----_______-

32Y VIO/I VELI

HOT IN RUN ANDSTART

_____

RED/ GRN

BV ELI

HOT IN RUN ANDSTART

FUSE F70 30A

INTERIOR LIGHTS SYSTEM

BYELI

ABSPUMP MOTOR RELAY

SWITCH

BRN fil 20

DISTRIBUTIONBOX

RED

EXTERIOR LIGHTS SYSTEM

DATA LINK CONNECTOR

1, FRONT POWER

FUSE F27 5A

_____________________

BRAKE (LIGHT LIWITCH

_ zJ

----------------

GRNI I BLU/ I VELI

(

FUSE F27 i5A

---

HOTAT ALL TIMES

+G202

WHT/VIO

REDIGRNIYEL

GRN/BLU/VEL

BRN/BLK

RED/BLU/YEL

BRN/WHT/VEL

BLU/RED

WHT/VIO

39 6 7 2 12 15 13 14 3

BRN RED/BLU/YEL

20 5

BRN/WHT/YEL 1

BLU/VIO YE~b ENGINECONTROLS . TRANSMISSIONS SYSTEMS BRN/RED

RED/BLU

BFNIRED

BRN/GRN

RIGHTFRONT (SOLENOID VALVE

BRN/GRNIYEL

II SOLENOID

YEL RED/GRN/YEL BLU VEL/BLK

BRN

BRN/BLK/YEL

BRN/GRN BRN/GRN/VEL BRN/BL U

BRN/GRY/VEL

BRNIBLU/VEL

REDIBLU

BRN

VEL/BRN

WHT/GRN/VEL

GRV/BLK/VEL

BLU/BRN

BRN

BRN/RED

BRN

WHT/RED

WHT/BRN

VALVE

II LEFT REAR

BRN/WHT

LEFTFRONT

) II SOLENOID VALVE

RIGHTFRONT

BRN BRN

BR ~N

BRN

24 25

G202 " SIC

BRN/WHT

BRN/BLU

BRNIBLK/VEL

SOLENOID VALVE

II LEFTREAR SOLENOID VALVE

II RIGHTREAR SOLENOID VALVE

RIGHTREAR

EL__ 14 ENGINE CONTROLS SYSTEMS

BRN/BLU/VEL

II SOLENOID VALVE

II SEPARATING VALVE

ABS H V DRAULIC UNIT

BLU/GRN

X1]ZI RED/GRN 1

BLK/GRN

BFN

BLK/BRN

;5 l X]7395 SLIP CONTROL MODULE (ABS/ASC)

j1313

a TTI

ACCELERATOR PEDAL[ POSITIONSENSOR 108819

G201 1_ G203 (3181) (3181)

LEFT FRONT SENSOR

LEFT REAR I .d-Jtla-dd ABS~~ SPERD SENR ESDO

RIGHT FRONT BS~~ SPEED SENSOR

RIGHT REAR ABS SPEED SENSOR

AUXILIARY THROTTLE POSITION MOTOR

ELE-124

ELECTRICAL WIRING DIAGRAMS

ABS/AST

1998 Except 3181, 318ti w/Traction Control (1 of 2) HOTINACCY, F_RUN AND START

HOTAT ALLTIMES

T FUSE F68 T 15A

HOT IN RUN ANDSTART

FUSE F3B T 30A

Ll_______________ 32Y

FUSE F21 5A

FUSE F10 'f 3DA

- 1 FRONT POWER DISTRIBUTION BOX I

_____________________-______---- J

RED/ I

VIO/I

HOTAT ALLTIMES

2DY

GRN/BLU/I YELI

RED/ : BLUI GRN/BLU/YEL

ABSPUMP MOTOR RELAY

ASSRELAY

VIO/YEL BRAKE ( LIGHT (SWITCH

_ sJ

BLU/RED

ENGINE CONTROL SYSTEM

BLU/RED

"BRAKESIG

% 32

BATTERY VOLT

SIGNAL EML-SIGNAL

j 4 5

TRANSINFLUENCE LREARSOLVLVSIG ADSSTEPMOTOR

ADSSTEPMO70R BE, SGND SENSGND BATTERY VOLT ABSPWRPROTECT FLY

SIGNAL ABS TRAVEL SENS SPEEDSIGNAL

SUPPLY LREARSOLVLVSIGI) ASCTHROTFLAP POT ASCTHROTFLAP POT ABCLECTRL

BB 18

BLU/RED RED/BLU/YEL

WHT/RED/YEL WHT/G N/YEL BRNIWHT

BLK/BRN/YEL .

BLK/GR

NCA

/YEL

NCA

REDIBLUIYEL

13 14

B BLU/GRY

WHT/GRNIYEL

REDIBLU/YEL BRNIBLU

WHT/RED

WHT/BLU

BRNIGRN

23 5D

WHT/BRN NCA

WH7/GRY

2B .

WHTIGRY/YEL

BLUIVIO

BEN/RED

NCA

29 31

NCA BLU/BLK

BRN/GRN/V EL

ABSLPCTRLl j34 IGNSIG j 35 38 SOLVLV LREARS0LVLV810 39 LFNTS0LVLVSIG % 40 41 SPDSIG

GRY/BLK/YEL

ASCTHROTFLAP POT PUMP MTRSENSSHIELD IDLESPDSIG THROTFLAP POSTN ASCSWSIG LFNTSOLVLVSIG SENSGND SENSGND ABSTRAVELSENSSIG FT FNTSOLVLVSIG

PUMP MTRSENSSIGNAL

j 49

7XOSIG -SIG l) RREPEEDSENSSIGNAL LRPEEDSENSSIGNAL RFSPEED SENSSIGNAL LFSPEEDSENSSIGNAL GROUND

7 B

GROUND

ins-

- ""

"" -_

-ME

""-

777

BRN/WHT/YEL BLK WHTIRED WHT/BLU BLU/BRN BRN/GRN . W-/BR NCA WHT/GRV WHT/GRY/YEL BLU/VIO . FN/FE

BRNIBLK/YEL BRN/GRN/V EL

18 19 20 21 22 23 24 25 26 27 2B 29

BN/BLU/YEL BRi

IGRY/YEL

SRN/WHT/YEL BL BLU

WHT/VIO WHT/YEL

4~~V'/~T 41 YEL j 47 dB YEL j

I I WHT/I YEL I

I I WHTII VIO I

DATA LINK CONNECTOR 10862 1

GRN/BLU/YEL

BRN j 1 BRN GROUND "ODULEI j 3 51 REO/BLU a SUPPLY 7 52 BRN/GRY ABS MTRRLY 55 BRN/BLK/YEL LREARSOLVLVEIG PUMP

SLIP CONTROL MODULE (ABS)

"" -

BLU/BRN

RTFNTSOLVLVSIG

"" -

"" "" ""

WHT/GRN

BLU/I BLK

B1-U/ DRY

ABSBRAKEPEDAL TRAVELSENSOR

NCA

RIGHT REAR ASS SPEED SENSOR

ELECTRICAL WIRING DIAGRAMS

ELE-125

ABS/AST

1998 Except 3181, 318ti w/Traction Control (2 of 2) HOTINRUNANDSTART - -IFRONT POWER IDISTRIBUTIONBOX FUSE F27

GRN/ I VIOI GRN/BLU/YEL

SLKIGRNIYEL AUXILIARY THROTTLE POSITION MOTOR

M BLK/BRN/YEL BLU/BRN

GRYIBLK/YEL RED/BLU/YEL RED/BLU/YEL RED/BLU/YEL BRN/BLU REDIGRN/YEL WHT/GRN WHT/RED/YEL WHT/GRN/YEL

GRN/BLU/YEL

BRN/WHT BLK/BRN/YEL BLKIGRNIYEL INTERIOR LIGHTS , SYSTEM

BRN/BLU/YEL BLU

+ .__--N-~

BRN/RED

BLU/VIO

RY/RED

BEN

G203

BRNIGRYIYEL BRNIWHT/YEL BILK 20 21 22 23 24 25 26 27 28 29

WHT/RED

RED/GRN/YEL

WHT/BLU BLUIBRN BRNIGRN

ni~~ milli

WHT/BRN NCA WHT/G RY WHT/G RY/YEL BLU/VIO BRN/RED

BRNIBLK/YEL BRNIGRN/YEL

WHTIREO

2 }3

WH / WHT/BRN

mill

AUXILIARY THROTTLE POSITION SENSOR

1915

WHO/GRNIVEL

BRNIBLU 15

WHTIGRY

It~36 BLK ___ _

I ~j5

BRNIRED

1 82 I %BO

11TIRE01YEL WHTIGRN

ENGINECONTROL MODULE(DME)

108622

_ BLK

LEFT FRONT INLETVALVE LEFTFRONT

II OUTLETVALVE

III

RIGHTFRONT

LEFTREAR OUTLETVALVE

III

}II

BRN/GRY/YEL 24 RED/BLU/YEL 17

III

BRN/BLU/YEL16

RIGHTFRONT INLET VALVE

III OUTLETVALVE

BRN/BLK/YEL25 45 WHTIGRY/YEL

I I I I

PUMP MOTOR SENSOR

BRN1WHT 19

TRANSMISSION CONTROL MODULE (EGS)

LEFT REAR INLETVALVE RIGHTREAR OUTLETVALVE RIGHTREAR INLETVALVE SEPARATOR

III VALVE

ABS HYDRAULIC UNIT

ELECTRICAL WIRING DIAGRAMS

ELE-126

ABS 1995-96 318ti w/o Traction Control HOT IN RUN ANDSTART

HOTAT I TIMES FUSE F46

L 1=A---------_---I

Y EL~

FUSE 3=A -------

HOTAT ALLTIMES

HOT IN RUN ANDSTART

Fl .

FUSE

'2'

30A -----------

SA-~

FUSE F2 SA ---

_-- BA------

OBNU

GRNI

HOT IN RUN ANDSTART

FUSE 2

GRNIVEL~

FRONT

POWER DISTRIBUTIONBOX

FUSE

BLU~

VIO

VIOIYE, BRAKE LIGHT SWITCH

61 BPN/I BLK

GRNIBLU

GRNIBLU/V EL

OPERATING VOLTAGE ~) 99

PEOIGPNIVEL

VOLT SUPPLY .TERMINALIS

VOLTSUPPLY,TERMINALIS

8 PE ./8

6262

INLET BRNIWHT/YEL RTFNTINLETVLVCTRL i 2

LFOUTLETVLVCTRL

~Ip

BRN

RED/BLU/YEL

BRNIWHT/YEL

Lai

BRNIGRN

BRN/GRN

B RN/RED

. FN/FE

BRNIGRN/YEL

BRNIWHT REAR AXLE OUTLETVLV }39 BRNIBLU REAR AXLE INLETVLVCTRLli2

JII

LEFTFRONT VALVE

~j (

FIGHT FRONT

L ~.}I .1

~ --

RF OUTLET VLV CTRL

VOLT "ON, HYDRAULICS

REDIGRN/YEL

BRNIBLK

ABSRELAYCTRLIi1

LFINLETVLVCTRL

GRN/ WIG

YEL

jll INLETVALVE LEFTFRONT

D11 OUTLETVALVE

D11

RIGHTFRONT OUTLETVALVE

II REARAXLE

OUTLETVALVE

BRN/WHT 10 . 11 FN/BL

II INLETVALVE REARAXLE

RED/BRNIYEL

II PROTECTION

OVER VOLTAGE

RED/BRN/YEL 12

ABS HYDRAULIC UNIT

6R N FLSPDSENSGND

FL SPEED SENS SIGNAL

FRSPDSENSGND

NCA

BRN

BRN/RED

YEL

YEL . .

NCA

BRN

BRN BRN

NCA NCA

LEFT FRONT ABS SPEED SENSOR

NCA

BRNN/E

NCA

~ ~

FRSPEEDSENSSIGNAL I) GROUND GROUND GROUND

RLSlEID61NSSIINIL PLSPDSENBGND PRSPEEDSENSSIGNAL RRSPDSENSGND TXDDIAG

SLIP CONTROL MODULE (ABS)

BRrv

BFN S BL ~7

14BLU ~ BRN j 1 YEL/BLK SS % YFLIBRN j 14 26 WHT/VIO l

LEFT REAR ABS SPEED SENSOR

NCA

RIGHT REAR ABS SPEED SENSOR

BFN~

YELIBLK WHTI VIO 20~

YELIBRN

N OA '

NCA NCA

G203

DATA LINK CONNECTOR 93371

l RIGHT FRONT ASS SPEED ~ SENSOR

ELECTRICAL WIRING DIAGRAMS

ELE-127

ABS/AST HOTAT ALLTIMES

HOTINACCY, RUN AND START

FUSE

HOTINRUN ANDSTART

HOTAT ALLTIMES

FUSE

L - ,30A --- ,15A _--- SAA-1 ---

HOTINRUN ANDSTART

FUSE

FUSE, POW F27 RIBUTI0 J gOX

30A

" ENGINE ICON7ROLS RED/ SYSTEM II), .FN YEL 1

G202

~F BRAKE J I LIGHT J SWITCH I I _ 3,I

" "

BRN BRN

8 24 9 X 21

BRN BRN RED/GRN WHT/GRY/YEL

GRN/ BLU/ VEL

2 BLU/RED

GRN/VIO

REDIBLU

GRN/VIO

20 T"'D

23,L

INSTRUMENT

I CLUSTER

ABS I IND I -I 21

EXTERIOR LIGM SYSTE M

DATALINK a' CONNECTOR

~7 WHT/VIO W' 18 BLUIED " 4 GRN/BLU YEL 25 RED/BLU 16 GRY/BLK/YEL X23 YEL/BLK X22 V E2~} ~BRN 19 B N ~ 20 RN 6 B~RU_~ ~6 BRN ~1 B~ RN/RED 2 BRN

REDIBLU

GRV/ BLK/ YEL

BLU/ RED

1997 w/ Traction Control

BRNdb

ASS CONTROL 2 MODULE

G202

HYDRAULIC UNIT

93-

LEFTFRONTABS SPEEDSENSOR

LEFTREARASS SPEEDSENSOR

RIGHTFRONTABS SPEEDSENSOR

RIGHTREARABS SPEEDSENSOR

ELE-128

ELECTRICAL WIRING DIAGRAMS ABS/AST 1998 w/ Traction Control HOTINRUN ANDSTART

. .TAT ALLTIMES

L USE

USE

16 RED/ GFN

I I

HOTINACCY, HOTAT SUN AND START ALLTIMES -------------------

I FUSE

FUSE 12 SA

F38 30A

--GRNI 8LU/ YEL

HOT IN RUN AND START

F46 16A-

4 ---------- v----------,

pRN/ VIO

-1 YEL

G RN/ BLU/ YEL

ASS IND

(

I I

INSTRUMENT CLUSTER

--I

I I(

------

FRONT POWER IDISTRIBUTIONBOX

I FUSE F10 --0

I I

20T RED/ BLU

I I

BRAKE 'LIGHT (SWITCH

GRY/ BLK/ YEL

EXTERIOR LIGHTS SYSTEM

7 )

GRN/BLU/YEL

RED/GRN

116

GRY/BLK/YEL

BLUIRE1=

RE0/BLU

11 BR 22

BRN

BFN

BLU

WHT/VIO

WHT/VIO _ _ _

119

YEL

X20

BRN

X21

WHT/GRY/YEL

X22

YEL/BLK

7 23 8

YEL/BRN B RN

X24

DATALINK CONNECTOR

BRN/RED

ENGINE CONTROLS SYSTEM

BRN

ASS CONTROL MODULE/ HYDRAULIC UNIT

rf,

108620

G202'A_'G203 (31811) (318,323, 328, M3)

G202 ''G203 (31811) (318,323, 328, M3)

-o

1E1, 01 .1 l -202 (31811)

tG203

(318,323, 328, M3)

ELECTRICAL WIRING DIAGRAMS

ELE-129

Air Conditioning & Heating

1992 (1 of 2)

HOTAT ALLTIMES

~ - BLK/WHT

12 BLK/WHT -VE=1=LESPEED I

INSTRUMENT CLUSTER

--~

HOTAT ALLTIMEB

fiFUBE 19

BS~ELK/GRY BS

I I) I )9B I 7e I 1 I---1

VIO/GRN

HOT IN RUN OR START

FUSE 31 BA ---

HOTAT ALL TIMES

FUSE 23 BA ----

HOTINACCY HOTAT RUN OR START ALL TIMES -----ROWER FUSE BE IFRONT DISTRIBUTION 39 15 ( BOX 7 .6A BA 7 30A ---- .~------_ -22¢r

VIII

JII

WATER VALVE (ASSEMBLY

BLK/BLU BLK

6 BLK/BLU

ENGINECONTROL MODULE (DME)

TRANSMISSION CONTROLS SYSTEM

r----------, FUNCTION LIGHT-RECIRCI

I I 1 1 I I

HOTAT ALL TIMES

FUNCTION -16" FEAR DEF06 FUNCTION LIGHT-A/CI IEAROEFOG61I PIRCIRCULATIONSWI Al CSWITCHI

BRN/RED

)2 3

BRN/YEL

WHT/GRN

WHT/RED

Z B

WHT/BLU

Wi SPNIRED

MIX ACTUATOR

EVAP TEMPI )22

HEATER TEMP-LEFT~ lG HEATER TEMP R

HT'

GRY

YELIRED

26 YEL/SLU A

STARTINGSYS STARTERSIGNAL I 2 GENERATORSIGNALI CHARGINGSYS 3 GRN/YEL IGNITION[) 5~YEL/VIOO LEFTWATERVALVE(

GRt

NIBLU .

1) I)6 /BRN GRN ~ VENTSOXI }9 1 ) 10 I ) 11

GRN

MINEmmmmml

RED/GRN

RIGHTWATERVALVEI 12 YEL/SRN I BATTERY BATTERY ;15 FEWYEL 16 BFNN GROUNOI 17 BR GROUND( O/GRY L 18 V ECM(

I) 1) 20 NOMINALTEMPVALVE-RIGHT( NOMINAL TEMP VALVE-LEFTI NoMINALAIRFLOW VALVE

YEL/WHT

YEL/BLU

YEWBLK YEL

INTERIORTEMPSENSORI 24 1)25

GROUND( 2B l----------Ja INTEGRATED CLIMATE REGULATION CONTROL MODULE

BRN

G202

INTERIOR LIGHTS SYSTEM

BEN

G203

8848 1

GRN 20

CONTROLPANEL

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-130

ELECTRICAL WIRING DIAGRAMS

Air Conditioning & Heating 1992 (2 of 2)

r I

HOT AT ALL TIMES _ --~IIGNITION (SWITCH

I I

OFF

START(

ACC RUN L---_--1'J

REDIGRN BLKIGRY

r Iw Q

G202

BLOWER RESISTORS

MAX

LO 1

THERMA L LIMITER

--T

. -/GR

TEMPERATURE SWITCH ~1)ABOVE99 1 2 DEGC 2) ABOVE91 3 Y.Y 2 Y DEGC

GRN

W/O PARK NEATINO VENTILATION W/P~

ARKHEATI VENTILATION

GRN

ON-BOARD COMPUTER

RE O GRN

-{ RE

AIC COMPRESSOR

12 13 M 1S

BRN/RED GRY BLU

GRNIBLU

YELlV10

FE ./.FN

YEL

RENE SRN 3 BLU 2 BLKIBLU ANXaIARY FAN MOTOR

I'.

Sri

I -~g I H WT " I -

IRECIRRC RECI 'LAP ACTT

BLU

RECIRCFLAPACT

~IFRESHFLAPACT

11"i1111111111 "1"111"1""I111

BRNIYEL

I I

FLAP PCT W~ I RECIRCCFLAPA

:~ -

BLK/WHTIYEL

YEL/RED YE LI BLN YLIED E R

r -------I

VDITAO E FOR REC FLAl RE -{IVOLTAGEFORMIXFLAP RE~ VOLATAGE FOR FRESH FLAP 4(

BLK/RED/YEL

GRY BLK BRN ORG

BLK/BLU

BLOWER MOTOR

FRONTPOWER DISTRIBUTION BOX

OFF

2 [

BLOWER SWITCH

BER LOW RELAY

~IFRESHFLAPACT GRY 12 ~PRESHFLAPACT BLU 13 FRESH FLAP ACT YEL/RED 14, IVOLTAGEFORROTSW

EL/V10 BRN/V

17'

I I I I

DA A LINE DATA LINE VENT FLAP SWITCH INTERSENS BLOW PCT

REAR BRNIYEL 20 GGtR ~~FEARDEFOGGERACT DESOGTEM BLU/BLK 22 23(ICOMPRESSORCONTROL BLU IDASHVENTMIXFLAP ~R G GASH VENT MIX FLAP

H ZS I I YEL

28 C

DASH VENT MIX FLAP

1"11111"11111"1111

1111111mil 1111111

IDASHVENTMIXFLAP L - - - - - - - -- J INTEGRATED CLIMATE REGULAT ON CONTROL MODULE

BRN / RED

MIXING ACTUATOR VEL/RED 1

7JIIIII11111~IIII~~~~

PI 14THEATEXCHANGER TEMPERATURESENSOR BRNIORG

BLU 1

NORMALSPEED RELAY

88482

HIGHSPEED RELAY

COMPRESSOR CONTROLRELAY

FRESHAIR FLAPMOTOR

DASHVENTMIXING FLAPMOTOR

RECIRCULATION FLAP MOTOR

EVAPORATOR TEMPERATURESENSOR

OUTSIDE TEMPERATURESENSOR

ELECTRICAL WIRING DIAGRAMS

ELE-131

Air Conditioning & Heating

1993-95 Except 318ti (1 of 2)

2 ILK/WHT 1=ERICLESPEE=I1 j

HOTAT ALLTIMES

BLK/WHT

FTFUSE 20

INSTRUMENT CLUSTER 316

I ---I1 85+ I I )68 I I I )48 174 , I-__I

325 6~ 5

LK/GRY

VIO/GRN

BLK/BLU

HOTINRUN ORSTART

_ ALLTIMES HOTINACCY RUN OR START HOTAT

HOTHOTAT ALLTIMES ALLTIMES USE AUXI FUSE USE FUSE FUSE FUSE 31PUSE 23 39 16 41 46 , , ,BOX 3_ -_ S--_ Y 1Bx 12y" 22 FRONT 2x(1995) POWER DISTRIrtBUTTON O BOX

' .SA---

L 3-"---2 ="--- -20 x

WATER VALVE ASSEMBLY

, r ,LIARY - j L 4 -J

¢I

47BBLK

BLK/8LU

ENGINECONTROL MODULE (DINE)

HOTAT ALL TIMES

TRANSMISSION CONTROLS SYSTEM

r---------FUNCTION LIGHT-RECIRC I)1 \2 ' FUNCTION LIGH-REAR DEFOG IG FUNCTION LIGHT-A/C, 4 REARDEFOGSW, 5

EXCEPT 19953181

119953181

B RN/RED B BFNIYELL

W T~~ E ~ . I AIR CIRCULATION SWI W~ WHTIBLU I A/CSWITCHI 77 I BFN I GROUND, 9 10 G~ RYIBLK I GROUND, 11 BRN/ORG I GROUND, A 1 12 BR N/BLU I OUN D j I VOLTAGE FORM -FIXACTI 13 YEL/GRN. I 10LTAGEFORFUNCLIGHTSI 14 G~ - INTERIOR II ILLUMIIAAT10N111-25-12 LK LIGHTS B

)

CKP/RPMSIGNALI j18 VEHICLESPEED, j19 INDEPENDENT VENTILATION, 20 MIXACTUATORI

EVAPTEMPI j22 23

OUTSIDETEMPI

HEATERTEMP-LEFTI j?4 HEATER TEMP-RIGHTI j25 26

SYSTEM

ELK BLK/WHT BLKEL BRN/RED GRY BL YEL/RED YEL/8LU

I) A I l BL K/G~RN STARTER SIGNAL ~--2

GENERATORS]GNALI

BL .

Nil

BLKI WHTIYEL

b STARTING SYSTEM

HARG(NG SYSTEM

I' 4 GRNIYEL ~ GRN/BLU

IGNITION, LEFTWATERVALVE,

YEL/VIO

GRSRNAn

I) 67 I ,B

PARK/HEAT VENT SIG,

I,11

YEL/BRN

I)13 14Y BATTERY

RED/YEL

RIGHTWATERVALVEI

BATTERY

,VARIABLE

1~ 6=RN

GROUND,

GROUND, 17 ECM!

CAMSHAFT CONTROL MODULE

B VIOIGRY

~19

NOMINALTEMPVALVE-RIGHT,

I) 221 Yj EL/WHT

NO MINALTEMPVALVE-LEFT,

YEL/BLU

BAN

YEL/=LLK NOMINAL AIR FLOW VALVEI 23~ T24 YEL INTERIOR TEMP SENSORI ~ , 25

I I

GROUND,

L---------INTEGRATED CLIMATE REGULATION CONTROL MODULE

)

a I G203 INTERIOR LIGHTS SYSTEM

G203

7449 3

ELK/

I RED 15,I

REDJYEL

CONTROLPANEL

ELE-132

ELECTRICAL WIRING DIAGRAMS

Air Conditioning & Heating 1993-95 Except 318ti (2 of 2) BLOWER SWITCH

BLOWER MOTOR

BLOWER RESISTORS

THERMAL LIMITER

REDIGRN 2 G RN 5 GRN 6 REDIGRN B BLK/WHT/VEL 4

REDIGRN

BLKIGRY

BLKIBLU

5 B

GRY/BLK

PARK HEATING/ VENTILATION RELAY BOX

BLK/WHT/YEL

J.-~~

SRN/ORG

ON-BOAR COMPUTER BRN

" rI

RED

YEL/GRN

BLK WHT

YEL

yy 12

BLU VEL RED

YEL BLU

14 .1

VEL RED GRNIBLU

y8 y7 .

YEL/VIO

7 B

BLU

YEL

WHT

GRV

12, ` 13

BLU -LIRE D

I !

s~l 6 I IRECIRCFLAPACT

WHT DRY

BRN RED CRY

3 4 ( iVOLATAGEFORFRESH FLAP

BLK/REDIYEL

AICCOMPRESSOR

-------_

VOLTAGEFORRECFLAP VOLTAGE FORMIX FLAP

RED RED

8 9

IRECIRCFLAPACT

I RECIPC FLAP ACT IRECIRCFLAPACT

I FRESH FLAP ACT IFRESH FLAP ACT

I FRESH FLAP ACT I FRESH FLAP PCT

IVGLTAGEFORROTSW 15 I COMPUTER !~WHT/VEL ~IIDATALINE DATAJl WHT /VIO 16 LINES i DATA LINE VEL/VIO 17 VENT FLAP SWITCH BRN/VEL 18, 1

l~C

BRNIYEL

!A~~I1011111~!~lu_ Jt

1 2 I

REAR BRN/YEL 20 ( DEFOG GER~ ' IREAPDEFOGGERACT SYSTEM BLU/BLK 22 ( REDIGRN 18 ICOMPRESSORCONTROL BL U 2 3~ BLK/RED I y9 DASH ENTMIXFLAP GRV 24 SPIN 20IOASHVENTMIXFLAP L WH7 25 `IDAS .VENTMIXFLAP ABOVE BELOW YEL 26 ODASHVENTMIXFLAP B 11 .P6 . 30 BAR gLK/GRV . A INTEGRATED GLIMATE It REGULATI ONCONTROLMODULE ABOVE BELOW 2 .6 21 BAR BLU/BLK L- - - - - - - - - - BAR VEL/GRN 2 BELOW 158AR GR BLK/ N GRV/BLK 3 } BRN ABOVE 18 BAR DR./- 1 PRESSURESWITCH 1994-95 MIXINGACTUATOR

I I

BRN

AUXILIARY FAN MOTOR

MEMINMEM

I I I I

~~~Jl~li~i~ I

NORMALSPEED RELAY

74494

HIGHSPEED RELAY

COMPRESSOR CONTROLRELAY

F RESHAI~R LAP MOTOR

DASHVEN~TMIXING FLAP MOTOR

RECIR FLAP MOTOR

2j ,

EA PORPTOR TEMPERATURE SENSOR

RIGHTHEATEXCHANGER TEMPERATURESENSOR 6PN/ORG

BLU I OUTSIDE TEMPERATURESENSOR

ELECTRICAL WIRING

DIAGRAMS

ELE-133

Air Conditioning & Heating 1996-97 Except 318ti

HOTATALL HOTATALL HOTATALL HOTATALL TIMES TIMES TIMES TIMES I--.BEUSE FUSE FUSE I a+ za as L J3'% . __

HOTATALLTIMES _ r --, IGNITION (SWITCH I I I START( I LOCK ACC RUN I I L______Y'J

~' 19

GRN

I o

HOTINRUN ANDSTART

HOTATALL TIMES - ,FRONTPOWER FUSE DISTRIBUTION 4I (BOX A __ _ 0-_I

HOTATALL TIMES --I AUXILIARY FUSE FUSE 4B I I BOX L 40 -J

-FUSE +s

¢I74I

N Iq

0l w

~' Iq

~' I G'

VEL/VIO

2 NC A l~ -

G202

. EL/BR

NCA WATER VALVE ASSEMBLY

1 BLK/RED/YEL

BLO W ER RELAY A/CCOMPRESSOR

BLU

II I_ 9FN ' G 100

BLU

I B-CYL

} BLK/

I BLK/BLU

4 BLK/BlU

BLK/RED/VEL 2

Mill

0101mmmmimi

BLLU

R E D/GRV g

X1 "" 1

BLU

AUXILIARY FANMOTOR (6-CYL) -BRN G100

-111""1

BLKIBLU 5 ORN/BLU 4

AU %ILIARV 7 FAN MOTOR

RED/GRN

HIGH SPEED RELAY BLK/GRN

8 BLKI R GRN ISLU

(NOT USED)

GRNIR D 6I BLK/BLU 2 NORMAL SPEED RELAY BLU/ BLK

~~ NCA .2

(NOTUSED)

BR N

GRN/VEL

RED/VEL

WHT/VIO

BRN

G203

GRN/BLU

RED _SRN YEL

PRESSURE SWITCH WHT/VIO

7 ~-~

DATALINKCONNECTOR

III

AUTOMATIC CLIMATE CONTROLMODULE

TEMPERATURE SWITCH

4-CYL 4 6

8-CYL l 3g

BLK/BL

_YEL GRY

BLK TRANSMISSION CONTROLS SYSTEM

_ ELL, WHT

744 `I

VIO/GR

1~ I

BLK/GRY

BLK GRY

REOIWHT

BLK GRN

GRV/VIO

BLK/8LU

\I lI I l

ENGINE CONTROL MODULE "

RED RCULATION FLAP MOTOR 87878

REAR RECIRCULATION FLAP MOTOR

REGULATIONFLAP MOTOR

DEFROSTER FLAP MOTOR

LEFTHEAT EXCHANGER TEMFSENSOR

LEFT HEAT EXCHANGER TEMPSENSOR

m OI

m 01

OUTSIDE TEMPSENSOR

EVAPORATOR TEMPSENSOR

BLKIWHT

2 ~~VEHSPFED I

INSTRUMENT CLUSTER

1)BELOW2IBAR 2)ABOVE 30BAR 3)ASOVE2 .6BAR 4) BElO W 1 .8 BAR S )ABOVE 6B AR 6)BFLOABOVE 8 7)40YLBOVE9 DEGC C BCVL : A ABOVE 8D 8) 4CYL: 8EG C 6CYL'ABOVE 91DEGC

ELECTRICAL WIRING DIAGRAMS

ELE-134

Air Conditioning & Heating 1998 Except 318ti

HOTATALL =M~S

HOTATALL HOTINRUN HOTATALL HOTINRUN HOTATALL TIMES -=Tf~RTES 6S=ART TyMES -- -- -- - - - - - 1FRONTPOWER (DISTRIBUTION I ~ FUSE20 FUSE31 SE=35E1 BOX 730A ~,L`Y.--3OAA ------------ -

HOTATALLTIMES

I I I LJ OFF/ ACC

TTTml

7Y GRNI

TI I"

GRN/SRN .RN) (OR RED/ N

NCA

IE40 140A

gUXILIARVFUSE BOX

LIVID

NCA I~

GRNI FED/

4 BRN BR N ?- " ---aIG202

RED( GRIN,

EL BR

BLK/BLU

' 2 GRN/BRN ~.YJIOPARK U ~}~VENTILATION BLOW ERRELAY ~ VENTILATION ION 11 B BLUIRED

Gl00'Il7 - PR -~

BRN

M 1

G10~ RN ~

VEL/RED VEL/BLU

BLK/WHT

BILK

GRY/RED

8 9

BLK/WHT/YEL BLK/GRN

VIO/GRY

BLU/RED

GRN/BRN

BRN

BRN/ORG

23 24

BRN GRN/VEL

RED/VEL

WHT/VIO

YEL

GR N/VIO

BLK/GRY

RED/GRN

GRN/RED

6 -CVL

STARTING CHARGINGSVSTEM

(6 CYL)

, 4-CYL

GRNIVIO 4

¢I

mIU BLKIBLU 2

IJ NORMALSPGED RELAY

BLU/ BLK

BEEN

~~m

VEL/VIO

BRN

(NOT USED)

INTERIOR LIGHTSSYSTFM

YEL

RED

14-CVL

BLU

DEFOGGERl POWERANTENNA SYSTEMS

I6-CVL

BLK/GRN

VEL/BRN

BLK/BRN (ORBLK/GRY) 5

BRN/VEL

HIGH SPEED RELAY

BLU/BLK

BLU GRY

BLK/

WHT

BLK/BLU

2 COMPRESSOR CONTROLRELAY

AUXILIARY FAN MOTOR (4-CYL)

BLU

4-CVL

FLU DRY

I BL

BRN/=EL

1 2

BLK/RED/VEL

AUXILIARY FANMOTOR (6-CVL)

BLOWERMOTOR

16 17

RED/GRY 6 BL}

6-CYL

FINALSTAGEUNIT

NCA

GRN/VIO 4

AIR CONDITIONING COMPRESSOR

GRN/BBN

Ian

FIGHT IjIIVALVE WATER VALVE ASSEMBLY

6 GRN/BRN(ORFEDIGRN)

)~LEFT VALVE lII

GRNI

e GRN

IT--~

RUN

}

HOTATALL TIMES

- -

,IGNITION ISWITCH START

I I

AUTOMATIC CLIMATE CONTROLMODULE

VEL

4-CVL

~YJ PARKVENTILATION CIRCUIT

IF EQUIPPED

" ~ ~B=K~ ~3fi{ I BLK/BLU 36 74 I

I I

VIO/GRY 69

19,

BLKIBRN(OR BLK/GRY) 11

BL K

GRVIVIO

4 II -

TRANSMIS IION

FRESH AIR FLAP MOTOR

16` i

REDIWHT

SYSTEM BLKJWHT 2 I I "-[ VEHSPEED - I XIZ I _--

RECIRCULATION FLAPMOTOR 101446

REARRECIRCULATION FLA 'MOTOR

REGULATION FLAP MOTOR

i 9 ~ .1w,

DEFROSTER FLAP MOTOR

m O ¢ ~w~~ II

LEFT HEAT EXCHANGER TEMPSENSOR

> m m F~~--~~ II

INSTRUMENT CLUSTER

SIGH T HEAT EXCHANGER TEMPSENSOR

OUTSIDE TEMPSENSOR

EVAPORATOR TEMPSENSOR

ELECTRICAL WIRING DIAGRAMS

ELE-135

Air Conditioning & Heating 1995 318ti

HOTATALLTIMEB--

HOTAT ALLTIMES

HOTINRUN OR START

HOTINRUN ORSTART

HOTAT ALL TIMES

HOT AT ALLTIMES

BLOWER RELAY

OFF

GFN/=RN

GF N/RED BL~K

, ~7 11

GEN

NORMAL SPEED RELAY

BLU

G~RN/BRN

BLOWERBWITCH

REDIGRN

BLU

2 B

REDIGRN GRNIBLU BLKIGRY

(NOTUBE D) HIGH SPEEO RELAY

GRYIRED

.1 19 OFF

CLIMATE

VIOIGRY

1)ABOVE99 DEGC 2)ABOVE 91 DEG C BLK

INTERIOR LIGHTS SYSTEM

GRN/YEL

BEN

BLK/GRN

TEMPERATURE SWITCH

OFF

RED/YEL

AIRCONDITIONING COMPRESSOR 77720

AUXILIARY FAN MOTOR I

ELE-136

ELECTRICAL WIRING DIAGRAMS

Air Conditioning & Heating 1996 318ti

OTATALLTIMES__ r H- - USE I

'I IGNITION I SWITCH

START I

OFF

HOTAT ALL-TIES r FUSE 1

30A

HOTINRUN _0_1START _

HOTINRUN _ OR 7START

(7yI ' . 5A

HOTAT HOTAT ALLTIMES__ AL_LTIMES _

77--FUSE ---

FUSE --

196A

FUSE -

30=-

,FRONTPOWER DISTRIOUTION 'BOX

ACC " RUN I L--_---YkJ GRNT

GRN

./BEN GR

BRNN

al'G202

N/SRN

BLOWER RELAY

BLOWER RESISTORS

M BLOWER MOTOR

GRNIBRN

U24--(( RE

BRN

aI G201

BLK

/C BLK/

RED/WHT 57 GRY68 BLK/GRY VIO/GRY

85 89

BLK/6LU

I \I

I I I I I II I

I iI

ENGINE CONTROL MODULE

AIR CONDITIONING COMPRESSOR 87839

ELECTRICAL WIRING DIAGRAMS

ELE-137

Air Conditioning & Heating 1997 318ti

r II II

HOTATALLTIMES_

OFF

BRN

GRN/BRN

.1 )2

GRNIBRN

BRN

71GNIT'ON S WITCH

START ACC "

RUN

I I I

HOTAT HOTINRUN ALLTIMES _ _ __OR START _ FU SE FUSE 20 23

HOT IN RUN ORSTART

HOTAT ALLTIMES

I L --_- --5A-__ FUSE 18

1.5

HOT AT ALLTIMES

FUSE 39 =_--_

3 -_J FUSE 41

FRONT POWER

l BOX Box

+G202

BLOWER RELAY

NORMALSPEEDRELAY

HIGH SPEED RELAY

BR= G201

BLKIBLU

_BLU

GRY/RED

BRN 1IABOVE88 DEGC 2)ABOVE80 DEG C BLK/GRN

AUXILIARY FAN MOTOR 3

TEMPERATURE SWITC

RECIRC

,10 RRDEFOG

L----'

.=N +

RED/YEL

+100 - BLK

GRY

1 24

BELOW 15 BAR

BLU/BLK

GRY/YEL

DEFOGGER SYSTEM

ABOVE 2 .6 BAR

BELOW 21 BAR BLKIGR

BRN

BELOW ABOVE 1 .5 30BAR BAR PRESSURE SWITCH

B CONTROL SWITCH GRY/RED BLK/ 2

ABOVE 18BAR

BB-K/GRN

BRN

SCLIMATE CONTROL WITCH ILLUMINATION

REDI GRY

I 1

I I I I I I I L__I

BlK/G RV

VIO/G RV

69 36, I

-LK/BLU

ENGINE CONTROL MODULE

INTEGRATEDHEATINGAND CLIMATECONTROL MODULE

TRANSMISSION CONTROL MODULE

SOLID S7A7E EVAPORATOR TEMPERATURE SENSOR 87847

FRESHAIR RECIRCULATIONMOTOR

TEMPERATURE WHEELSWITCH

WATER VALVE

COMPRESSORCONTROL RELAY

AIRCONDITIONING COMPRESSOR

ELECTRICAL WIRING DIAGRAMS

ELE-138

Air Conditioning & Heating

1998 318ti

HOTAT

_ _ _ , IGNITION ALLTIMES II FUSE (SWITCH

HOTATALLTIMES

r --I I

OFf

~ ACC "

HOTINRUN HOTAT ALLTIMES __ ____ POWER FUS~ FRONT FUSE FUSE DISTRIBUTION 23 16 39 ( BOX ---SA----~7 .6A-I

HOTINRUN &START

20 =0= --

START i

RUN

HOTAT ALLTIMES _&STAR -(AUXILIARY r PUSS FUSEBOX 48 ~0= -

+ G202

BI= "

G .W .R .

GRNIBR~

-P"-

BLOWER RELAY

Gr RNIBRN

G RNIRED

BL ~

DR.

BLU

1} S G RNIGRV NORMAL SPEED RELAY

BLOWERSWITCH

BLO WER RESISTORS 1 NCA

BLK/GRY

GRN/GRV

HIGH SPEEDRELAV

BLKIBLU

211

NCA

1)ABOVE88 DEGC 2) ABOVE DEGC 6o BLKIGRN

AUXILIARY FAN MOTOR 3

RN BLK/GRV

DOUBLE TEMPERATURE SWITCH mI G10D

RROElGG

BRN

INKS CONTROL SWITCH 1

GRV/RED BLKIG -RED/I

WNT 57 I GR~V~~I

BLKI 2

BRN

BLK/

VIO/GRV

CLIMATE CONTROL SWITCH ILLUMINATION

I 1

GRN/RED

B2 RN

VIO/GRN

BRN ,

fig GB

III

DULE(DME)

BLU/BLK DRY t7 >I

INTEGRATED HEATING &CLIMATE CONTROLMODULE

¢ >

OOm¢m l. 6 ~S 6 /S 2 .h

~I .

EVAPORATOR TEMPERATURE SENSOR 101298

BLKIBLU

I II L_ _I ENGINECONTROL

BLKIIGR=11

FRESHAIR RECIRCULATIONMOTOR

TEMPERATURE WHEELSWITCH

WATER VALVE

COMPRESS RCONTROL RELAY

BLKIBLU IS % CONDITIONING COMPRESSOR-TRANSMISSION CONTROLMODULE (EGS)

.CA] j

ELE-139

ELECTRICAL WIRING DIAGRAMS

Park Ventilation 1998

rHOTATALL_TI_ME_S --(( IGNITION SWITCH (OFF ACC

I L---

HOTATALLT_IM_ES

START( RUN

GRN1

-_J

~ '+FUSE20 30A

I I

FRONT POWER DISTRIBUTION BOX

---I 20Y X10016 RED/GRN (OR GRN/BRN)

7 GRNT

UNCOUPLING DIODE

I I

18 119 120 121 123

BLK/WHT/YEL BLU/RED GRNJBRN BRN BRN BRN

BRN I

AUTOMATIC CLIMATE CONTROLMODULE

I BRN 1 -9- G202

I -IL G201 1 B RNIBRN }2 G ® 33 BL GRN/YEL FINALSTAGE UNIT

RED/GRN 2 GRN 6

BRN

1 BRN(

NCA

GRN/ ,1 YEL

NCA

BRN/ 1 YEL

BLOWER MOTOR

BLOWER RELAY

1 G201

RED/GRN 8 , "

BLK/WHT/YEL 4 PARKVENTILATION RELAY

BLK/WHT/YEL 14 r (VENT L - - - J ON-BOARD COMPUTER

101447

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-140

ELECTRICAL WIRING DIAGRAMS Airbag (Supplemental Restraint System) _HO_T _AT ALL TIMES OFF

!START START I 1

NCA AI, 7 WHT1110 WHT1VI0 20, ~ " ~~ DATA LINK WHT EL 1 CONNECTOR B " 12 VIO

T%D XD

Ru1~T

IGNITION SWITCH

- ACC_(

22 VIO

VIO

VIO POWER " -i DISTRIBUTION VIOI 15~~. X-141~

-----

INS ICRT IF.1ENT

NDIC TO~ I 1

14T= BLU/BLK

`9 BLU/BLK X74

LEFT FRONT IMPACT SENSOR

RED

VEL

YEL

YE-

1 11

WHT

RED

110

YEL

?, YEL

11992-93 Early Production

RIGHT FRONT IMPACT SENSOR

DRIVER'S AIRBAG GAS GENERATOR

88996

HOTATALLTIMES START I I

OFF

AWL

BLU/BLK

~~ 8

GKBF

BLU11 IO /VEL

ACC

LIT

14 I X16

VIO/WHT

POWER DISTRIBUTION

ABF-

NCA

TXD

ABBF+

WWH

BRN

1OERNERATOR

G203

DATALINK CONNECTOR BLU/BL

PASSENGER'S AIRBAG GAS GENERATOR

BLUIG X782 3

BLU/VIO/VEL

SUPPLEMENTAL RESTRAINTSVSTEM CONTROLMODULE

8900D

~~ DRIVER'S

m0e

Xanz

CONTACT RINGS WHTIVIO

BLU/BLK

12 BLU/VIO/YEL

JBLU/GRV ABBF- ~-

GKF

17NCA 1

XZ83 T/VIO

~DETECTOR OY

BRN

WHT/RED

10 YEL/BLK

,BF+

INSTRUMENT CLUSTER

PASSENGER'S

WHT/RED

BLU/BLK

1 BRN

58E

__I

RUN

IOJ V15 XLB

(IGNITION SWITCH

18RN

DRIVER'SSEAT BELTSWITCH

BRN " -# G203

14 ~SEATBELT WARNING LAMP XIZICONTROL INSTRUMENT CLUSTER

1993 Late Production

ELECTRICAL WIRING DIAGRAMS

Airbag (Supplemental Restraint System) 25 _ ~` (FRONT FUSE ~1FUSE PDYdER F42 [ F43 (DISTRIBUTION 7.5A 7 5q !BOX (- -- - 24Y 26Y I !

SUPPLEMENTAL RESTRAINTS SYSTEMCONTROL MODULE R 31E

VIO/GRN

IRN

\1 I

SLU/BLK

BLU/VIO/VEL

ABBF+

WHTfRED

BLUIBLK

O= 3 5;

N " BRN

PASSENGER'S SEATBELTSWITCH CA

NCA

BRN

NCA

BLU

BRNIBLK

WHTIFED

PASSENGER'S AI RSAG GAS GENERATOR

WHT/VIO

BLU/VIO/YEL ORBLU/REO/ 12 WHT 3 -{

"U SOCCEATPANCY DETECTOR 2

G303 (4-DOOR) G404 (318TI)

BLU/VIO/VEL 2 ORBLUIPEO/W HT i 1 BRN

O >3 1

G203 (2-DOOR) 1

CONTACT-GS

GKF

X16

1J VEL/SRN

TXDI )9

INSTRUMENT gIRBAG CLUSTER INDICATOR/

BLUIBLK

14 1~ BLU/GRYORS LU/BRN ABBF- ,

ABF-

VIO! 15 I I

SBE

VIOI

>3I

dI' G3 03

AWL )T/ GKBF )

_ HO_TA_TALL_TIMES IGNITION I I START OFF !SWITCH I ! RUN ACC

VIO

VIO 23 __

DRIVER'S SEATBELTSWITCH

G201 (1994)

BRN/BLK 1 995 LATE PRODUCTION AND1996

G404 (1995-1996)

(7 m01 G404 ~ G203 ( X (31871)8TI) 318T1)

X17

SRN

m00

DATALINK CONNECTOR

----- I ISEATBELT I ( WARNINGLAMP (CONTROL I IJ INSTRUMENT CLUSTER

-,CODELECTRONICS _ -ICONTROLMOOULE

1994-96

ELE-141

ELECTRICAL WIRING DIAGRAMS

ELE-142

Airbag (Supplemental Restraint System) 1997

_HO_TA_TALLTIMES

FI IGNITION

(START

OFF

I I RUN ACC L- ---_

(SWITCH

-1

I I

V IOT VI O'

I I

HOT IN RUN ORSTPRT

FUSE F27 SP

FUSE F12 7 .5A

DISTRIUTION ISTBIOBO%

I I

vIo 23 B BRN 31EI~

AWL

_X1S_ 6 _ ,IF INDICATOR I

G303

"/ BLU/BLK

INSTRUMENT CLUSTER

VIOIGRN

VIO/GRN

VIOIGRN VIO/GRN

VIO/GRN

GKBF

VIOIGRN

SEAT 1 BRNIORG

B RN I ORG

DDETECTOR

al" G2O3

SENSOR

PASSENGER'S SEAT BELT SWITCH

TXD

WHT/VIO

/BLK

ABF "

BRNI

22~ DATA LINK CONNECTOR

ABF-

VEL/BRN

BLUIGRN/VEL

G203

NCA

BLU

)

IRIBAGGAS GENERATOR

G203

CONTACT RINGS

GKF

~1 . . . .

4 !SEATBELT WARN, . LAMP X~ (CONTROL I---_ _ T INSTRU MEN CLUSTER

BLU/VIO/VEL

1 BR= " BRN/ORG

+ G203

I I

DRIVER'S SEATBELTSWITCH 15

S BE

LIB

WHT/RED

VEL

ABBF-1)

CS SUPPLEMENTAL RESTRAINT SYSTEM CONTROL MODULE 89015

YEL

VEL

NCA

RIGHT SIDE AIR BAG GAS GENERATOR

LEFT SIDE AIRBAGGAS GENERATOR

BRN

BLU

. .

BLU

BRN

I2/

B~R

2~ NC

.FN

ABBF,

BLU/BLK

BLU/BRN

BLU/BR

WHT/BLUORBLK/BLU

WHT/YELORBLK/YEL

.RN/ .L .

N PASSENGER'S AIRBAG GAS GENERATOR

.RN/BL

(EX .318T1) (3

I-_

I BODYELECTRONICS CONTROLMODULE

ELECTRICAL WIRING DIAGRAMS

ELE-143

Airbag (Supplemental Restraint System) 1998

HOT IN RUN ORSTART

HOT IN ACC, RUN ORSTART

1FRONTPOWER FUSE DISTRIBUTION BOX USE -I52 12 -- -~_ _ - J

14TXID017

24YX19018

vio

vio/ GRN

23 l. Xlb INSTRUMENTI CLUSTER ~

AIRBAG INDICATOR

LU'8=K

BLU/RED/WHT 3

(318ti)

G201

G20~3 (318, 323, 328, M3)

BRN/ORG

BRN/=E RG 3

VIO/GRN

" VIO/GRN

PASSENGER'S SEAT BELT SWITCH

WHT/VIO

WH71VI

BLU/VIO/ YEL

8V~ 10/GRN 8 BLU/RED/WHT

14y X1~

'x35. BLUII BLK

SEATBELT INDICATOR

Viol GRN

viol

GRN

DATALINK CONNECTOR

SEAT OCCUPANCY DETECTOR DRIVER'S AIRBAG GAS GENERATOR

ORG

viol GRN

3Y WHTI RED

BLU

1`('

ORG

DRIVER'S SIDE IMPACT SENSOR

ORG

CONTACTPINGS 2 BLU/GRN/V EL

BLU/GRNIVEL 3

(31811)

G201

BR N IORG

BRN/OR

G20~ 3 (318, 323, 328, M3)

BLU/8

BLU/BRN

WHT/RED BLU

.RN

VEL

B RN

WHTIBLU

, 21

WHT/YEL

BRN/BL={I

BLU

BRN

' ;/

VEL

. .

YEL

BRN

SUPPLEMENTAL RESTRAINT SYSTEM CONTROLMODULE

108623

EI-/-N

YEL/BRN

YELIRED

YELIFED

BLU/RED

BLU/BFN

BLU/BRN

LEFTSIDE AIR BAG GAS GENERATOR

. .

BRA)

BODY DYELECTRONICS CONTROL MODULE OO

G201 (318ti)

PASSENGER'S AIRBAG GAS GENERATOR

BLU

BRNI ORG

DRIVER'S SEAT BELTSWITCH

BLU/BLK

2 B~UI=101YEL ~ q V

DRI VER'S SIDE PYROTECHNICAL BELTTENSIONER

PASSENGER'S SIDE PYROTECHNICAL BELTTENSIONER

RIGHT SIDE AIR BAG GAS GENERATOR

G203 (318, 323, 328, M3)

YEL

PASSENGER'S SIDE IMPACT SENSOR

ELE-144

ELECTRICAL WIRING DIAGRAMS

Anti-Theft

1992-93 3181 & 3251 Alpine System HOTATALLTIMES RU FU SE

16 REDIGRYIYEL

HOTINACCV .RUNANDSTART FU

--------

X14415

26 VIO/WHT

FRONT POWER DISTRIBUTION BO%

X10018

BRN/GRY/YEL

23 Ell

RED/GRY/YEL/

I --_

I LFDROPEN INSTRUMENT CLUSTER

VIO/WHT

LK/GRN~I

ANTENNA

-CRASH CONTROL MODULE

CA NCA VIO (

BLK

RED NCA LU/YEL

(< 5E

BRNIBLU

NCA~ NCA , 36 I I "' I ' 7 e

BRN/BLK BIKIB

NCA

" NCA

NCA

3 ~2 53 3

BRN/ORG BRNBRNIGR

NCA

LU/GRN

RED(GRV IVE L VIO/WHT

BRN

" -ar

I I

BRNIGRY/V EL

BLUI} GRN/ EL WHT/RE DIYEL BRNIW

WHTIREDIYEL BLUIPED/YEL " B=N

TEPIOR LIGHTS SYS

BRN/WHT

BB=K NN=A

I__

I LFDROPEN I

1 ANTI-THEFT

DRIVER'S DOORHANDLE SWITCH (WITH COLOIWET PACKAGE)

BRN' 1 G203

BRN/BLK BLKIBLU

HORN

BRN/BL2K

BRN/BLU/YE.L1

ON-BOARD COMPUTER RELAY

BLK/BL21

(ALPINE) ~SWITCH ~ONTACTR C MBR'S fl LOW-NOISE MICROPHONE

BRN/OR01

BRN / BRN/BLK/

BR NT BRN/GRVIY EL 2

SW H

RIGHT REAR DOOR CONTACT

VIO

VER'S DDOTO AN .

1 G

::I

LED BRNI

8900 2

ELK

VIO

INE)

oil

IRIJ

"" I 1

G203

G310

G312

lol l 1 .203

I ANTI-THEFT

BRN

CONTROLF7 MODULE tALPINE)

BPNIREDIYEL

2 TRUNK LIGHT SWITCH

NCA

2 54 2

BRN/REDIYEL B II ~ " ~~ILFDPHNDL

X13025'

VVVV=O

BRN/BLUIYEL 2 ~ IRFDROPEN X13412 I BRN/BLK 2 7I I REAR DR OPEN X1341

0 BLU/RED

NCA

G203

CENTRAL LOCKING MODULE

I I

ELECTRICAL WIRING DIAGRAMS

ELE-145

Anti-Theft

1992-93 318is & 325is Alpine System HOTA_TA_LLTIMES_ _ _ _HOTINACCV,RUNAN_DSTART 1FRONT POWER WER FUSE FUSE DISTRIBUTION FS F43 I BOX -S----------- 5A___J Is XIOOIS 2s xj oD+B RED/GRV/VEL VIO/WHT

I L

RED/GRY/VEL

VIO/WHT

BRN/GRV/VEL

I I

LFDROPEN -II ____

2 il

23 xLZ

ANTENNA

BLK/GRN/YEL

INSTRUMENT CLUSTER

CRASH CONTROL MODULE

NCA

VIO S BRN

~2 ~3

BLK/ f ;HT .

NCA

~-~INCA GA 1

VIO/WHT BRN/ORG

NCA

1 5

BRN/BLU/YEL

NCA

B 7, 7

(NOTUSED) BLU/GRN/VEL

BLU/VEL BLUIGRN

WHTIRED/VEL

BLU

BLU/RED/YEL

BRN/WHT

5 72

BRN/RED/VEL

x I3D25

_VIO

+ 3203 I'

SRN/GRV/YEL

RN/BLUIVEL

. BRN/BLU/VEL

BLK/BLU

NCA

SPUN

BPN/GRV/VEL

NCA

RED/GRV/VEL

BLU/RED/VEL

BRN/WHT

INTERIOR LIGHTS SYS

IANTI-THEFT ILFDR HNDL

CENTRAL LOCKING MODULE

BRN/WHT

_NCA

TRUNK LIGHT SWITCH

NCA

ANTI-THEFT CONTROL MODULE (ALPINE)

I I I

BPN/BLU/

IBOARD IOMPUTER (HORN RELAY

. .L(

----

PASSENGER'SSIDE POWER WINDOW MODULE

BLK/BLU 2

BRNIBLUIYELI 2

ANTI-THEFT HORN (ALPINE)

BPN/GRV/YEL PASSENGER'S WINDOW RETRACTION DOOR HANDLE CONTACT

DRIVER'SSIDE POWER WINDOW MODULE

LOW-NOISE MICROPHONE

BRN/RLU/YEL 2.

BRN/RED/VzLI BL

VIO

BRN/BLUIY2LI

BLK

VIO

BRINt

DRIVER'S HANDLE ITCH (WITH COLD/WET PACKAGE)

BRNI

89003

BRN/GRV/VELI

BRN

PASSENGER'S MB SWROH

DRIVER'S MB SWITCH

~' BRINt

BRNI

3203

G203

I II 24 II ANTI-TH EFT 25 I

BRN/RED/YEL S X13012

_ BILK

IL FO RO PE N

,(III RFDROPEN II

BRN/GRV/VEL

WHT/RED/YEL .

-- - _ I_

BRI

ORIVER'S WINDOW DETRACTION DOOR HANDLE CONTACT

ELECTRICAL WIRING DIAGRAMS

ELE-146

Anti-Theft

1994 Early Production Alpine System HOTINACCY,RUNANDSTART -IFRONTPOWER rfi IDISTRIBUTION I F43 E BOX 6A _J

26Tx19D3a VIO/WHT /

VIO/WHT

BLK/GRNIVEL

2 ,I

ANTENNA CRASH CONTROL MODULE

VIO BRN

NCA

V~0/WHT BR NBRN/ORG

BRN/G

BRNIGRYIYEL

Y/YEL

NCA

BR~

NCA

BLUIYEL

N CA

~V=L 12 BR 17

BRN/ BLU/V

NIBLUIVEL

E-211 I

BLU

WHTIREDIVEL 17

WHD/1=EL

BLU/GRN 10 BLU /WHT 1L B LU 11 BRN

EXTERIOR LIGHTS SVS

BLU/RED/YEL

I I

BRN/RED/VEL

1 II

X13923

VIO

I BRN/WHT

0=K NCA

.RN/81K 4 , X1+Z54

TRUNK LIGHT SWITCH

NCA

L______) BODY ELECTRONICS CONTROL MODULE (ZKE I V)

ANTI-THEFT CONTROL MODULE (ALPINE)

21 l ' ~

DRIVER'S BRN/BLKI Z 8RN/BLU/VE2~ NCA I I1/1/1/ ~ ~

SWITCH

AM .R ~DWIOTCH

~J LOW-NOISE MICROPHONE

NCA I 1 BLK

BRN/BLK) 2

'SWITCH MB

I ERNI 1

NCAI

G203

BRN/GRY/VEL 21 J. T SWRCN MB

8 RN

BRN/

8341 3

DOOR HANDLE SWITCH (WITH COLO/WET PACKAGE)

1 BRN 1

BLK

VIO

(

VIO ~C

SRN

A-

G310

G312

ELECTRICAL WIRING DIAGRAMS

ELE-147

Anti-Theft

1994 Late Production Alpine System HOTATALLTIMES

r ~ L -

-, AUXILIARY FUSE BOX IS

HOT IN ACCY . RUN AND START r -1 FRONT POWER DISTRIBUTION BOX F43 E

WHT

REDIGRY/I YEL

VIO/ WHT

REDIGRY/ VIO/ YEL

RED/GRY/YEL

BLK/BLU

WHT/GRN

FED/RY/YEL

HORNRELAY

REDIGRY/YEL

VIOIWHT BRN/GRY/YEL

SRNIGRY/ EL22~ BRNIBLU/ EL 3

BRN/BLUIYEL 25N/WT BLK/BLU

BRNI_

I I

I iII

X13254 WHTT/SRN

I I I

II L --I

VTOIGRNIYI

VICIGRN/YEL

X10244 ANTI-THEFTCONTROL MODULE

X1D1B2

BODY ELECTRONICS CONTROL MODULE (ZKE IV)

VIOIGRN/

~I i

ON-BOARD COMPUTER

BRN VIO/G BLK/ /GYELI BLU ,

[7]

ANT1-J THE FT HORN

DRIVERS DOOR SWITCH

BRN /

BRN/

VEL~

[7]

WHTI PASSENGERS LEFT REAR

SWITCH

CONTACT

BRN

G312

///111/

DOOR

BRN I

BRN /

VIO/G

WHTI .

RIGHT REAR DOOR ~ CONTACT

YELI JJ11/ ~~..

YELI 't

RADIO MICRO SWITCH

.+1+11/i.

ENGINE HOOD SWITCH

BRN

G(4 DOOR) G203 (2 DOOR)

8341 4

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-148

ELECTRICAL WIRING DIAGRAMS

Anti-Theft

1995-97 Except 318ti Alpine System HOT AT ALL TIMES

r I I

-1 AUXILIARYFUSEBOX FUSE I

I 1_ . J

HOT IN ACCY, RUN AND START r -, FRONTPOWER E I I DISTRIBUTION BOX

.69

PEO/GPY/ YEL BLU/REDIYEL

REO/G

RED/GRY/YE

BL_

W H~

RED/GRY/YEL

YELI

WH7I

DHANDLE SWITCH

G200

BRN/WHT

BLUIGRN/YEL TRUNK LIGHT SWITCH

HORN RELAY

CRASH CONTROL --MODULE

SLUIREDIYE WHT/RED/YEL

i -- 1 ! I

X132B3 I BRNIRED/YEL

~~ll 71~l! !~ (

4 6

BRN/GRY/YEL BRN/BLU/YEL -

BRN/WHT

BLK/BLU BLU/GRN/YEL

WHT/RED/YEL

BLUIPED/YEL

11 12

BRN/WHT BRN/REDIYEL

X1+02s ~( 1

.BRN/GRY/YEL

BRN/BLU/YEL

BRN/WHT

WHT/GRN

VIOIGRN/YEL

X .14192 L --I BODYELECTRONICS CONTROL MODULE (2KE IV)

VIO/GRN/YEL VIO/GRN/YEL

L --I

ON-BOAFOCOMPUTER

BLK/ BLU LOW-NOISE MICROPHONE

ANTITHEFT HORN

BRN I

DRIVERS DOOR JAMB SWITCH BRN

PASSENGERS DOOR JAMB SWITCH SRN I

(4 DOOR) G203 (2 DOOR) 83388

LEFT REAR DOOR CONTACT BRN

RIGHT REAR DOOR CONTACT

RADIO MICROSWITCH

BRN I

SPIN

BRNI

SPIN

G200

ENGINE HOOD SWITCH

ELECTRICAL WIRING DIAGRAMS

ELE-149

Anti-Theft

1995-97 318ti Alpine System HOTATATLLTIMES r `FUSE,AUXILIARVFUSEBOX

I T 2s RE

RED/GRV/YEL

WHO/GRN

RED/ GRV/VEL

I I

F47 15A

HOT IN ACCY . RUN AND START PRONTPOWER PUBS, DISTRIBUTION BOX F43 5A

I I I I L __J

25D

XIDD]B

viol

RY/ V EL

WHT

RED/GRV/I VEL

VIOII WHT

BLUeL1IGENIYEL

-1

1 CRASH CONTROL MODULE

HORNRELAV

C NCA

RED

NCA BRN

V10/

N` C

BRN

SRNIREDIVEL

BRN

BEN/GRV/ YEL2

NCA

BRNISLU/

NCA

BLK/

NCA

BLU

BRN/WH

NCA

BRN

1 I

BRN/BLU/=_3

X]~254 I

I I I X~-D~s2 L -_ I

WHTWRT/I VIOIGRN/I

VIOIGRNIVEL

BODY ELECTRON CS CONTROL MODULE (ZKE IV)

VIOIGRN/~

ON-BOARDCOMPUTER

1 W/OOCM

W/CCM

BRN/GRV/I YEL

BRN/BLU/ VEL

VIO/GEN/ VEL

BLK/ BLU

LOW-NOISE MICROPHONE

63688

G400

G203

ELE-150

ELECTRICAL WIRING DIAGRAMS

Anti-Theft 1995-98 EWS II

HOTATALLTIMES LOCK ACC

START I

* RUN

HNALLTIMES - ALLSTART HOTAT

ISWIT

I I I

1 I I

T JA

RED/GRNI

GRN/GRYI

RED/GRN J

GRN/GRS~

GRNISLK / 1.~

HOTINACCY, RUNANDSTART

F USEFUSE FUSE F45 1I P46 (199631811) /(EXCEPT F28 6318H) JIA ---- 7'5A

FUSE F31 A

~Y'J

HOTINRUN

FRONTPOWER DISTRIBUTION BOX

VIOIYEL NCA

VIOIYELI

IGNITION SWITCH

AUTOMATIC I TgqNSMISSION I RANGESWITCH I (OOPF(LOW)) (1 ON (HIGH))

NCA

2 NCA 7 90260 X B RN/ORG 3 VIOIYEL 2 BLU 1 I

DATA LINK 20 CONNECTOR

WHTIVIO

TRANSMITTER MODULE (EWS II)

STARTING , SYSTEM

1 2 f 3~ ~4 ~5

BLKIYEL WHTIVIO GRN/BLN GRN REDIGRP

TRANSMISSIONS SYSTEM

7BRN ~ BR ~B BlK/GRN ~9 BRNIBLK X 10

BODY ELECTRONICS CONTROL MODULE (ZKE IV)

} i 2 BLK it

EXCEPT 3188

13 BL X 16 BLUIRED/VEL ~15_ BLK/GRN SU

X1659

BLK/GRN BLK I

ELECTRONIC IMMOBILIZER CONTROL MODULE

BLK/VIO

ON-BOARD COMPUTER

END NECONTROL MODULE(DME)

93580

TAATALLTIMES HOTAT ---7IGNITIONALLTIMES

HOTINRUN ALLSTART

AUTOMATIC TRANSMISSION RANGESWITCH (A/T) STARTER (A/T) 7T IMMOBILIZATION SWITCH (MIT) 2I (MIT)

GRN/BLK

L I

DATA LINK CONNECTOR

HOTINACCY, RUNANDSTART

I I

20_W_HT1VI0 _

STARTING , SYSTEM

G203~ 6201 -

TRANSMITTER MODULE(EWSII)

BRN/ BLK I

1 2 3 d

5 6

BLKYEL WHT VIO GRNIBLK GRN flE0 GRN

BLUIRED/YEL ,

TRANSMISSIONS SYSTEM (A/TONLY)

ANTI-THEFT CONTROL MODULE (ALPINE)

6R=--,+G202 ,7BLKRN" )9 RN BLK X 10 11 12 BL~ X 13 BLU ~ 14 BLU RED/YEL 15 BLK GRN 1'8r-28 X16so I GRN(OR ELECTRONIC BLK( BLK/VIO) IMMOBILIZER BO I

93583

--__--

MODULE

BLUIGFIN 10~I

.M3 ENGINECONTROL MOOULE(OME)

BLK/GRN

.X10184 I BLU/RED/YEL 4 I

X 32i` l_ EXCEPT 3186

BO .YELECTRONICS CONTROL MODULE (ZKE IV) BLK/GRN

_ __

ON-BOARD COMPUTER

ELECTRICAL WIRING DIAGRAMS

ELE-151

Anti-Theft Forced Entry 1998 Except 318ti

KOTAT ALLTIMES

HOTINRUN, ACCYANDSTART

FUSE, AUXILIARY IFUSEBOX

, FRONTPOWER

I DISTRIBUTION BOX I FUSE F43 I BA I L __J ./'l VI

RED/GRY/I YEL

WHT

VIO/ WHT

{E z ~C-(( NCA

((

4 L I'1 C A A BB

~ 3-C~

BRNIBL~UIHT BRN y I X]9259

BLU/BLU

11RA 12

WNCA

WHT/RED/YEL

BRNIGRYN/G/

BRN/BLUIYEL B

I II

1 -- 1

BRNIGRY/YEL

~~ 9 l

NCA

vIO/wH

/WHT

I i

I ( Xi0Ufl2 L --I

WHTIGRNN7

BODY ELECTRONICS CONTROL MODULE (ZKE IV) BLK/ BLU

ANTI-THEFT CONTROLMODULE

BLK/I BLU B

BLK/ BLU

REDIGRY/YEL

I _ l J, 2 BLK/BLU 4~ WHTIGFN HORNRELAY

BLUI

WHT

BLUI

VIOIGRNI YELI ANTITH EFT HORN

.// BR WHTI

BRN/ WHT EXTERIOR LIGHTS SYSTEM BRN/GRY/I YELI

E V]TFUNK HOOD LIGHT SWITCH SWITCH

HS DOOR JAMB SWITCH v BRN

.RN I 1 G100 104760

a T

SLU/RED/I YELI

H S DOOR HANDLE SWITCH

BRN

SRNIBLU// YELI

IAIII GER'S SWITCH, JAMB

BRN

BFN I

BRN

SRN/ I WHTI

BFN/ WHT

[

BFN

BRN

I I

BRN I

GS03

G312

G203

LIFT REAR DOOR CONTACT

FIGHT ~ REAR DOOR CONTACT Y BRN

ELE-152

ELECTRICAL WIRING DIAGRAMS

Anti-Theft Forced Entry 1998 318ti -

NCA

HOT AT

HOT IN RUN,

NCA

ALL TIMES

AC CY AND START

I I _J

FUSE F47

LOW-NOISE

15A

MICROPHONE

BL K VI 0

-1

F I

AUXILIARY FUSE BOX

-1

FUSE F43

FRONT POWER DISTRIBUTION BOX

RED/GAY/

VIO/

YEL

WHT

BLU/GRN/YEL

I--

1 LED

CRASH CONTROL RED/GRY/ /

MODULE

VIOL

BRN/GRY/YEL

NCA INSTRUMENT CLUSTER BLU/RED/YEL

ANTENNA ELECTRONIC NCA

i~1

IMMOBILITER

.RED/GRY/YEL

CONTROL MODULE

VIO/WHT

BAN

BRN/GRY/YEL

BRN/BLU/YEL

BRN/BI

8L~ U/GRN/YEL

LCD

l~lJ

BAN

/YEL

S 10 BL U/RED/YEL 11

BRA

BREL

BLU/RED/YEL

X13253 BRNIRED

VIO/GRN/YEL

MODULE

I II I I I

I I

I I I I I

BODY ELECTRONICS CONTROL

BLK/ BLU

VIO/GRN/

YEL

BRN/

WHT

ANTI-

BRN/GRY/ YEL

BRN/BLU/ YEL

HOOD

HORN

BAN

MODULE (ZKE IV)

ENGINE

THEFT

104754

3~I

WHT/RED/YEL

10244

CONTROL

X13254

LCD 9~W

ANTI-THEFT

I SWITCH

BAN

-97

A L

G100

G201

SWITCH

~ JAMB

JAMB

SWITCH

BAN

SWITCH

BAN

G404

47 G201

ELECTRICAL WIRING DIAGRAMS

ELE-153

Horns HOTAT ALL TIMES

/ FUSE FB

HOTAT ALLTIMES

FRONT POWER

I DISTRIBUTION BOX

1OFF II

L- ~-- - -I 16T

RUN

ACC

2 VIO~

VIO

L --

RED/WHT/YEL (OR RED/GRY/YEL)~ " RED/I G RY/Y6L I ,,,111,,,

2 "

VIO/BLU 2

1992-93

HORN SWITCH

BAN

POWER DISTRIBUTION

. 4 8RN/RED 1,

VIO/BLU

LEFT HORN

--J

VIO) 8

VIO/BLU

IGNITION ISWITCH

RIGHT HORN

BAN

BAN I L G111

BAN

! G202

68419

HOTATALLTIMES ------FRONT FUSEF8 (POWER 15A DISTRIBUTION ------ J BOX

HOTATALLTIMES ___ r ---

i STARZ-OFF

RED/ GRY/YEL

IGNITION ,,WITCH

RUNT

ACC

2 VIO

VIO " -POWER DISTRIBUTION RED/I GRY/Y6L I VIOI 8 ,,,lll,,,,1 .. ( HORN RELAY -------------- .---

2 VIO/BLUr " VIO/BL2~

YT l

:G111

(J) IgyO,/R RIGHT HORN

BRNI 83485

LEFT HORN

BAN

1994-96

4}' BRN/RED

VIO/BLU

BRN " BRNI iG202

ELE-154

ELECTRICAL WIRING DIAGRAMS Horns

HOTATALLTIMES -~-FRONT `J FUSE F8 POWER 15A DISTRIBUTION LBOX 16

HOTATALLTWES

RED/ GRY/YEL "

viol

VPOWER DISTRIBUTION

RE 6/ GRY/YELVI O

HORN RELAY

----_-_---------~_ f

VIO/BL2~

VIO/BLU I

HORN SWITCH

LEFT HORN

BRNIREDI

RIGHT HORN

BRNI

BRN

BRNI

:G111

88646

~G202

HOTATALLTIMES

r- ~ - - - - -1 FRONT I FUSEF8 (POWER I 15A I DISTRIBUTION L Jk---- J BOX 167

I I I

RED/ I GRY/YEL I

L-

RU N

ACC

2 " VIe I

JJJ...1

VIO ~iPOWER DISTRIBUTION

HORN RELAY

-------------------

```((( I

VIOIBL21

VIOIBLUJ 8RNIREDl .JJJ,,,

JJJI'..

LEFT HORN

1 BRN BRN : 1 _ G100 104879

RIGHT HORN

HORN SWITCH

1 BRN

I I

--_J

VIO

RE DII GRYIVE6L 1

IGNITION (SWITCH

BRN BRNI i G202

ELECTRICAL WIRING DIAGRAMS

ELE-155

Wiper/Washer HOTAT ALLTIMES I

FUSE_ I F36 L0A 12`~I RED/BLU/VEL/

HOTINACCY, _ RUN _ ANO_START FRONTPOWER FUSE DISTRIBUTION BOX F76 ,~,15A

---- 2B VIOIBLK~ -18

VEHICLEI2 BLKIWHT SPEEDj}---- " BIGN=L XIZ

WASHER PUMP

INSTRUMENT CLUSTER

IBRN

1 SRN/GRN/YEL 2 BLKIWHT/YEL 3 BLKIRED/YEL 4 ~5 BLKIWHT ~6 REYV=L } 7 BR I 8 VIO~ g BLK 10 BRN~~ 1 7 BR~12 BLKI .13 BLKIBLU X 15 B

BRNIGRN/YEL , NCA SLK/W NC A BLK/RED/YEL 2 NCA

r"'ll' G202 I

B=N:

8.N

1992-98 USA Except 318ti

NCA

ORG I

WIPER/ WASHER MODULE(LOW III

WASH

BLKIBRN

BLK/GRY q

SINGLE OFF INTER

BLKIBLU

NORML~ 1

FAST

BRN(VIO

WIPER/WASHER SWITCH

1 BRNIORG

1 G203 t_ G202 (1997,98) IEXCEPT1997,98)

~ G203 88916

HOTAT ALLTIMES

HOTAT HOTINACCV, _ ALLTI_MES_R_U_NAND_START __ _ _ _ _ _ -~ IFRONTPOWER ,USE r TS FUSE ,IFUS_E I DISTRIBUTION BOX I / F36 F3 ~F6q l _-~I0A--_116A L _121A 12 X744TB 6 X14415 281 X1=6 RED/BLU/YEL REDJBRNl VIO/BLKI VEL _ VIof BLK VEHICLES 2 BLK/WHT SPEED NO; SIGNAL X1Z WASHER PUMP INSTRUMENT CLUSTER

~~ _ -- " I

BRN/GRN/YEL BLK/WHT/VEL BLK/RED/VEL q GRV/BLK BLKIWHT RED/BLU/VEL 77 BFN A VIO/BLK BLK/BRN IX10 BRNIV H77 BRN/V ,72 BLK/GRV

NCA 2

10 10

INTERIO LIGHTS SYSTEM

BRN/GRN/VEL BLK/WHT/VEL BLK/REDJVEL

ECA 4 N< NCA NCA

BR" cE' NCA

BRN JG202

BRN/VIO 2,

WIPERMOTOR

1998 Canada Except 318ti

WASH

BLK/BLU

BLK/GRV q

BLK/BRN

SRN/VIO

L--yl SINGLE OFF INTER NORML~

BRN

BRN I t G203

BLK/GRN 7 ( ED) ~EVS 1 ZG203

FAST

BF. I

WIPER/WASHER SWITCH

88985

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-156

ELECTRICAL WIRING DIAGRAMS

Wiper/Washer

1992-96 Canada Except 318ti HOTAT ALLTIMES -- -- - -

HOTAT ALLTIMES - - - - - - -

HOT IN ACCY, RUNANDSTART

HOTINACCY, RUNANDSTART

HOTAT ALLTIMES

1 NT IDRSTAIBOTIONBOK (F44/F55EF36E rF3 SE. . . . . . . . .i(F37 ..' E ~ E -----" 7-5L_11100030A 0- ___1L15A_______-__-____ -O-J --------____ ------3 X14416 1 6 -- 28I ------------12/ X3941H . RED/BRN/YELI RED/BLU VIO/BLKI VIOIWHTI RED/BLU/VEL

RIG HT PARKr LIGHT/LICENSE 130 PLATE LIGHT RELAY I -

BRN/VIO

BLK/RED

(EX 1992) (1992)

VIO/BLK

5 2

DAY/ BLK

BLK/GRN

I J

VIO/) WHT

RED/ BLU/ YEL

66 1,

INTENSIVE WASHER PUMP

8585By BAN

BRN/GRN

SAN TWINRELAY MODULE

s l

^ I

.112Y

BANI y G203

WIPER MOTOR RELAY

VIO/ WHT )

BLU/ BVEL

efi

WRIELPEAR Y

)2 )3 REDBRN/VEL ,5

BLK/BRN

)88

BR BLU/BLK/VEL

PARK

HEADLIGHT/FOGLIGHT CLEANINGMODULE

BRN/GRN/YEL BLK/WHT/VEL BLK/RED/VEL

q NCA 3 NCA

RUN

2 ryCq

" -~ 1 NCA WIPER MOTOR l5 '6

BBLU/BLK/VEL

~7 ;8

BLKIRE D

BLKGRN/VEL ORN BLK

1~0

BRN/GRN

~1 1

GR~

V/8 K

GRY/ BLK

1INTERIOR LIGHTS SYSTEM

)13 116

BLK/BLU

X15

BANIGRI IY.L

~12

BLK/BRN BRN/VIO

X17

STARTINGICHARGINGSYSTEM

BLK/GRN/VEL 7

BLK/GRN

BRN/VIO

BLK/BRN

BRNIBLU

INTE SIVE WASH

WASH

,18 ,19 I ~20

)21 '22 ' V10~ /BL 232 26 BLK

BLKIBLU

256 BLKIVI RG

v26

BLK/BRN

SINGLE OFF INTER

NORMAL

BK/VIO/YEL BLKIGRY

BLKIGRY

FAST f

WIPER/WASHER MODULE WIPER/WASHER SWITCH

VSPEEDI SIGNALI

BLK/WHT

X~ I L____J

INSTRUMENT CLUSTER 83025

8RN/ORG 1 G203

G202

ELECTRICAL WIRING DIAGRAMS

Wiper/Washer H_OTAT_AL_LT_IM_ES______________________H-OT INACCY_,R_UN_A_ND_START FUSE FUSE FUSE F36 F44 F3 '( _ - __ -__ __ - -- --- -. _ 1== . . . . . 3~121x1DD16 FRONT POWER DISTRIBUTION BOX 28YX1gIL19 67X1001A VIO/BLK! I .1

VIO/BLK

REDIBRNI YEL

WIPE R/ Q

NCA

NCA/

NC A/

.+ .

NCA NCAl

WA SH E SWITCH

NCA

7'/`

1995-98 USA 318ti

BLUIBRN I

WASHER PUMP

WIPER/ WASHER MODULE (LOW II)

REAR WIPER/ WASHER MODULE

I 1

G201

W/PER MOTOR

2_1 X17 11,7EHICLEIINSTRUMENT SPEED I CLUSTER IO -T-

I I I 1 G201

86888

HO_T_IN_ACCCRUN_ANND_ST_A_RT__H_OTA_TA_LL_TIMES H_O_TINTA_CC_Y,_RUNAN,DS_TA_RT FRONTr' rFUSi ~I FUSE ,FUSE 4FUSE, POWER -- F45 ----F36 --------[F44 -- CF3 IaISTRIBUTIONJ~ 30A 7,5A _ 30A,,,~~~ 15A~~,, BoxL___ _______ ___ 28Yx1D018 6Y XIOBI5 3D}~X70018 12 X78078 VIO/WHT REDIBLU/ VIOIBLKI REDIBRN I . YEL YEL .

RED/BLUI VIO/WHT YES VIO/WHT m WIPER ~30 MOTOR /

wo16L

RED/BLU/ YES 87

WIPER RELAY

1995-96 Canada 318ti

83619

G203

WIPER/ WASHER MODULE

ELE-157

ELE-158

ELECTRICAL WIRING DIAGRAMS

Wiper/Washer HOTATALLTIMES F~

HOT IN ACCY, RUN AND START

FFUSE us , .... ,lo lA . .. . .. ... . .. ..... . .. ..... .11SA -- - -~-"------ j 1111TI-1111IT-U-N ... ~.Y~ 6y~

I L

11 Y.L

RED/ BRNI YEL

: vlof NCA

PERfWASHFR SWITCH WIPEI REAR

NCAINCAI - S SRM

NCAI

SRM

I "I

YEL D

REOf -N/ YEL

Nl1T

IN,

NCAI

7~ SLUI , RN

-11

131-~ ,

GRY11 -

N IT

K~2

WH YELI

RN I: -

NCAI

moT,

t V.1,0,11 -RN RED y ELl

L. RN ''

REAR W11-1 WASHER MODULE

[4]WASHIR PUM

Sy LIGHT GR~ SWITCH

.1-K/1 R

LKI" RE YEL 20 NCA

NCA

' 5A :

...

G202

R'.1 BLUf

N HOTAT ALLTIMES

ASH IPER

.1-N/1 RN

R .11

vlo

L-.H

%.FdF]dUd

21 Qfl

R'1N.C 21t

8R' G2~1

LKT 1

1998

WIPERI Mo WASHER DU E (LCwII) LIQ 1' BRN I

BLKI WHI

N A

HEADLI HTIFOGLIGHT WAHERPUMP

~EMKEj Sp

NCAl G202

88892

i 'T i INST-RUMENT CLUSTER

L ST' - + G 1 oo

RN'

HOT IN RUN AND START FRONT POWER IUSE DISTRIBUTION BOX F24 10A j

GRNIBLK 8

GRN/BLKI 1 JETHEATER THERMOSWITCH

GRN[BLK(ORGRNlYEL)T GRNIBLK(ORGRN/YEL 2 N$

GRN/BLK(ORGRNly LEFTWASHER JETHEATER

2 NIAT

RIGHTWASHER fUJETHEATER

BRN, G202 -97 3119 (ALLOTHERS) (Z3) 88895

1993-98 Washer Jet Heater

ELECTRICAL WIRING DIAGRAMS

ELE-159

Wiper/Washer HOT ATALLTIMES

r I

FUSE1FRONT POWER I DISTRIBUTION BOX F3 30A J

6̀`y((' RED/BRN/YELT RED/BRN/YEj HEADLIGHT/ FOGLIGHT CLEANING MODULE (SRA)

1995-96 Headlight Washer I~ s WIPER/WASHER MODULE

88907

BLU/BLK/YEL 9

ELE-160

ELECTRICAL WIRING DIAGRAMS

Rear Window Defogger HOTINRUNAN

START

HOTATALLTIMES

USE 23 FUSE 6 i -fu- - - - - - - -- - --- --- - --- - ~2-07 --------------------GRNIBLU

REDfBRN

GPN/BLUF .RNl.L .t

4 -----------

ELK

I IHKR ER

- - - - - -IAN ENNA AMPLIFIER AM/FM

,CONTROL PANEL

NrA 25Y GRN(YEL I

BRNIYEL kHTIGRN I

21j,- BL . ------------GROUND -

GROUND

L BR INT

J--- -1

NCI

IC NLTEGRATED 'MAT

REAR REAR WINDOW WINDOW DEF GGER)EFOGGER ACTIVATION SWITCH GROUND

INCA

13AN I

4,k-

[VOLTAGE SUPPLY

RE R DE OGGER RE AY

--------

SLUIBLK I

IF ONT POWER 1 DISTRIBUTION BOX

REGULATION NTROL MODULE

I ~P~ GGER/ ANTENNA

NCA]

SUPP ESSION FILTER

_qtRUtD _j A

SRN 16

26 NJ X18156

3RN I G203

~CO G312 UPE)

-~ G201(1992 318 & 325 SERIES)

;t G310

- (SEDAN)

1 68 -156 HOT IN RUN AND START HOTATALLTIMES jSEJ F ONT POWER F F-U S-E - - - - - DISTRIBUTION SOX I ~ F23 6 1 CA i

0 REARDEFOGGER RELAY

SRN/YEL

BLU/BUK

INTEGRATED C [MATE REGULATION CONTROL MODULE II

SUK NCA

AT NCA

I (W/3 ANTENNA DIVERSITY) NCA NCA NCA NCA NCA

ANTENNA AMPLIFIER

REAR DEFOGGERI ANTENNA

~W3AU~ENNADIVERSITY) N2 CA NCA NCA

L DIVERSITY (W13 ANTENNA DIVERSITY) e

BRN

BRN.' G314 --I RADIO

I 2

WHT

I --i HIFIAMPLIFIER (W/TEN SPEAKER SYSTEM ONLY) 63564

(2 DOOR) G 13 (4 DOOR)

SUPPRESSION FILTER

ELECTRICAL WIRING DIAGRAMS

ELE-161

Rear Window Defogger HOTINRUNANDSTART ~c

HOTATALLTIMES

FRONT POWER

r' F23 E

L15A____--6'( IN GRNIBLU l RED/BR 4~

SE1 DISTRIBUTION BOX

F6 20A

REAR DEFOGGER RELAY

2Y BLKI 20

_ -I

BLU/BLK

BLK 26

REAR BLOW ER RELAY WINDOW

INTEGRATED CILMATE REGULATION CONTROL MODU LE

RED/BLK

REAR WINDOW BLOWER MICRO SWITCH BRN

SRN

NCA

N A

REAR WINDOW BLOWER

G314

"CA

WHT NCA

ANTENNA AMPLIFIER

T RADIO

O 16

-I

NCA NCA WH

INCA NCA NC

G314

BRN " .

(2 DOOR) G313

NCA NCA NCA REAR DEFOGGER/ ANTENNA

NCA INCA i l INCA ~I NCA . I

(4DOOR)

L -1 HIFI AMPLIFIER

I _

DIVERSITY

1994-96 Convertible

SUPPRESSION FILTER

BRN

SPIN

I BLK - ~E NCA -~E NCA

-- I

BODYELECTRONICS CCNTROLMODULE (ZKE IV)

WHT

(W/3ANTENNA DIVERSITY)

(W/ TEN SPEAKER SYSTEM ONLY) 64018

HOT IN RUN AND START r

HOTATALLTIMES

LlL______-

6T GRN/BLU4,~

FUSE FRONTPOWER I DISTRIBUTION BOX F6 J

FUSE F23

REDIBRN~ 6 REAR DEFOGGER RELAY

AUTOMATIC CLIMATE CONTROL MODULE 12

I-_-I

BLUIBL

INTERGRATED CLI MATE REGULATION

2 ILK

BLUIBLK

I, 4

BRN/WHT

HEATING CONTROL

BLK NCA N CA NCA NCA WHT NCA

1 (W/3 ANTENNA DIVERSITY)

ANTENNA AMPLIFIER

I I I

NCA

N CA - I N~ CA N~-

DIVERSITY (W/3 ANTENNA DIVERSITY) 1~ I I, 16

NCA NCA WHT

RADIO

F -I 12 I

--I' HIFI AMPLIFIER

88620

NCA NCA NCA NCA NCA NCA REAR DEFOGGER/ ANTENNA

NCA i

_ BODY ELECTRONICS CONTOLMODULE

THERMOSTAT

2OA

12T

WHIT

BRN SIRNI G314 (2 DOOR) G313 (4 DOOR)

SUPPRESSION FILTER

1997 Except 318ti

ELE-162

ELECTRICAL WIRING DIAGRAMS

Rear Window Defogger HOTINRUNANDSTART

HOTATALLTIMES FRONTPOWER r'~ FUSE ~~~jjj``` FUSE DISTRIBUTION BOX I ( F23 'f~ F6 L,ti5A~L20A I

GRN/BL Ur

z RED/SRtN

GRN/BLU(

RED/SRN

JJJII..

REARDEFOGGER RELAY

BT BLUIBL 10

2 BILK IRKS ( CONTROL ( SWITCH

1995-96 318ti

G203 SL

_NCA NCA _NCA INCA NCA INCA

ANTENNA AMPLIFIER

REAR DEFOGGER/ ANTENNA

(Wl3 ANTENNA DIVERSITY)

I 1 I I , 76 I I L__I

WHIT

RADIO

BRR

I, 9

WHT

-I

BRNi

! HIFI AMPLIFIER (W/TENSPEAKER SYSTEM ONLY) 83902

SUPPRESSION FILTER

G404

HOTINRUNANDSTART rTFUSE I F23

~~I

HOT~~~AT 1 1. ALLTIMES FUSEFRONTPOWER , I DISTRIBUTION BOX / F6

L ` ( 6_A_~ZOAJ 6I GRN/BLU " 4'k

IHKS CONTROL T I1

I I I

1 BRN

BRN I ~" B

G203

)Y 10 BRN/ EL

L_ -- I

~INTEGRATEDHEATING &CLIMATECONTROL

2 BLK W/ AERIA

W/O AERIAL

BLU/BLK 4

BRN/WHT

i BRNBR I CHI) L- __I REAR DEFOGGER SWITCH i

N-< " ~~I' G203

BLK N CA ;CA NCA NCA WHT NCA

ANTENNA AMPLIFIER

I, 2

_NCA 6 WHT

L__I RADIO

WHT

I --I' HIFI AMPLIFIER (10-SPEAKER SYS. CD PLAYER)

88654

REAR DEFOGGER RELAY

[jH

-4)

12T RED/BRN( 6j,

BLK BRN

HEATING CONTROL

REARDEFOGGER .! G404 NCA NCA NCA NCA NCA NCA REAR DEFOGGER/ ANTENNA

1997 318ti

ELECTRICAL WIRING DIAGRAMS

ELE-163

Rear Window Defogger HOTINSUNANDSTART

HOTATALLTIMES FUSE,FRONTPOWER DISTRIBUTION BOX FB

r, TFUSE F23

5A____---

30-J

GRN/BLU GRN/BLUj 4 IRKS CONTROL SWITCH I ---

. BRN/EL

2 BLK W/ W/0 AE RIAL AERIAL

ITEG RATEDHEATIN( E MATECONTROL

---I

BLUE

REARDEFOGGER RELAY

_ . .G201

BLKI

HEATING CONTROL

BRN/WHT

BLKJ REAR DEFOGGER

G201

REAR DEFOGGER SWITCH X1943 BRN ) 1 ~ XLS93

1998 318ti

BRNI 1

+ G404

3404

BLK 2 X1645

X380 BLK 1 X379 EL/BLU 1 VEL/GRN 2' I ' X1947 1 II~~IIIT

VEL/BLU 1 ~2 VEL/GRN ~3 WH X1949

ANTENNA AMPLIFIER

REAR DEFOGGER

O I __I 2 HIFIAMPLIFIER

WHT

--I

SUBWOOFER

104767

HOTINRUNANDSTART

HOTATALLTIMES rF - SE TFUSE,FRONTPOWER IDISTRIBUTIONBOX I F23 F6 I_,1SA--_-----;30A J 67X14 GRN/BLU GRN/BLU 4

AUTOMATIC CLIMATE CONTROL MODULE

RED/BRN REAR DEFOGGER RELAY

I ~ 12

BRN/VEL

WIAUTOMATIC CLIMATE CONTROL

I? S

BLU/BLK

BRN/WHT

W/O AUTOMATIC CLIMATECONTROL

THERMOSTAT I~ 4

I -- I'

2 BLK

NC A A ,f NCA~f

= NCA NCA

NCA~E NCA NCA~E NCA

1998 Except 318ti & Convertible

REARDEFOGGER/ ANTENNA

ANTENNA AMPLIFIER NCA _NCA _NCA NCA DIVERSITY (W/3 ANTENNA DIVERSITY) 1 } NC Ir N .A I I 16 WHT

I I

I BRNI I G312 1G310 (2 DOOR) (4DOOR)

RADIO I

__I

2 WHT

I HIFIAMPLIFIER

104762

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-164

ELECTRICAL WIRING -DIAGRAMS

Rear Window Defogger 1998 Convertible

. .TIN .UN ANDSTART

HOTAT ALLTIMES

FUSE F23

HOTINRUN . ACCYANOSTART

FUSE F6

FUSE F43

I L '=______- _D-____________ e x>--z 12 x366)-a 2s

GRN/~ BLU

GRN/ BLU 4

RED/ BRN

,FRONT POWER I DISTRIBUTION BOX

-A__J xi6niB

GRN/1 WT

GRN/ WHT REAR DEFOGGER RELAY

NCA NCA REARDEFOGGERI ANTENNA

NCA _ NCA _NCA NOA DIVERSITY (W/ 3 ANTENNA DIVERSITY)

I I I I

NCA I~ ucA

I~ I ,s

NCA wHT

BRN REAR WINDOW LOWER RELAY

SPATIAL SoU NO RELAY

ED[ RB-I

I~ 2

ANI BYELI

YIELI

BREL

VI O/YEL

x]31266 GRNIBLK

HIFIAMPLIFIER

.N/I .

RED/ BLK

YEL

BLOWER

BRNI

BRNI 1 6312

104784

SUPPRESSION FILTER

GRN/I WHY

-I

RADIO

BRN ELKI

NDOW

GRN/I BILK

31 f~

BRN

CONVERTIBLE TOPCONTROL MODULE

IREARWINDOW BLOWER MICROSWITCH

-ELECTRICAL WIRING DIAGRAMS

ELE-165

Instrument Panel

1992-97 Except 318ti (1 of 2) HOTATALLTIMES

_ __ __ __ _

I START

LOCK

ACC

RUN

L---

T GRN 11

18 /~

A23 A16

BRAKE FLUID IN D

I CHECK ENGINE IN .

A17 J,

EXCEPT 1997

SRS IND

1997 ONLY

81 FUEL CONSUMPTION METER

FUEL GAUGE

HEADLIGHTS SYSTEM INTERIOR LIGHTS SYSTEM EXTERIOR LIGHTS SYSTEM EXTERIOR LIGHTS SYSTEM TRANSMISSION SYSTEM

REDIYEL RED/YEL

WHT/YEL

WHT/VIO

BRN/RED

14 15

BLU/BLK VIO

GRY

BRN/GRN /V

BAN

YEL

SUPPLEMENTAL RESTRAINTS SYSTEM

EXCEPT 1 .92 . 1993

ENGINE CONTROLS SYSTEM

YEL

BRNIORG

ENGINE CONTROLS SYSTEM GRN/BLU BLKIWHT BRN/BLK BLK/RED

EXCEPT y 7992

CONNA 1 WHTIRED ~2

VIO/YEL

8R~N

BRNIYEL

4 5

GRN/BLU

BRN/VIO

GRIN BLU

BLU/BRNIYEL

B18

6 7

A20

YELIBRN

-K/FED

WHTIGRY

GRYIBLK/YEL LISP

13 14

GRN/PED BLU/VIO/YEL

WHT/GRN

VIO/YEL

BRNIYEL

BN/VIO

B 15 j

WHTIGRN

BLK/WHT

STARTING/ CHARGINGSYSTEM

BRNIGRN

20 21

GRYIBLK/VEL (ORBRN)

22 23

BLU/BLK BRN/GRV/VEL

9 0 11

12 13 14 15 16

BRN/YEL

BODY COMPUTER SYSTEM ANTI-LOCK BRAKES SYSTEM

HEADLIGHTS SYSTEM

ANTI-LOCK BRAKES SYSTEM (EX 1992 A 1993) ENGINE CONTROLS SYSTEM (1997 ONLY) BLU/VIO/YEL BFN BRN " GRY/BLK, VEL ANT ~`r~i LOCK W/OASC W/ASO GRV/BLK/VEL SY STEM ES (ORBRN)

1997 ONLY 4

~I G202

BRNIGRVIVEL

SEAT BELT IND

FUEL RESERVE IND

BRN/GRV OR BRN/GRN

INSTRUMENT CLUSTER

BIN/ VIO

BRN/GRN OIL PRESSURE SWITCH AL .^ 11

8299 1

WHTIYEL

GRNIVIO

RED/YEL

POWERTOPSSYSTEM

2 RED/ Y EL

iw .TIBLU

816

14 N1 Vlo OR

814

TEMP GAUGE

CHECK IND

EXCEPT 1997

2 VIO

EXTERIOR LIGHTS SYSTEM

BLK

HIGH BEAM IND

GRVIBRN

WHT/BLK RED/YEL

B24

FRONT 10. LT IND

BLU/GRN

21 22

B17 TACHOMETER

RIGHT TURN IND

ROLLOVER PROTECTION IND (CONVERTIBLE)

LEFT TURN IND

BLU/BRN

28 SPEEDOMETER

GRYIRED

A79

A22

ILL UM ~ (3 USED)

RED/WHT (ORWHT)

ACC RUN ------- -

7 CONVERT8 ISLE ONLY 9

CHARGE IND

PARK BRAKE IND

LOCK

HOT IN RUN AND START HOTATALLTIMES IGNITION FRONT UTION r FUSE FUSE I DISTRIB1000% (SWITCH LF21 ~F31 START L 5_A _-__J

[._~]

PARK BRAKE SWITCH

G202

GROUND

RA11FL11 U LEVELSW ITCH

ELE-166

ELECTRICAL WIRING DIAGRAMS

Instrument Panel

1992-97 Except 318ti (2 of 2)

HOTINRUNANDSTARTE___ HOTINACCY,PUNANDSTART HOT INACCY,RUNANDSTART __________-IFFUSE

B GRN/ BLU

15 20

WHT/VIO 1

DATALINK CONNECTOR

32 viol YEL

USE

IDSOTRIBUTIONBOX

____________ .T7.5AJ 30Y

BRNIYEL

viol WHT

FUELTANKI SENSOR" " -

YEL

LIESSSVSTEM

WHT/GRN

FUELLEVEL SENSORI

WHT/YEL WHT/VIO

FF"

REDIVEL 2

5A_____-TISA

WH7/VA N

USE

F23

REDIVEL REDIVEL

8RN/BLK BRN/BLK VEHICLE SPEEDSENSOR

WHT/VEL WHT/VIO BRNIRED

OIL7EMPESENSOR

YEL

RED RED

EXCEPT 1992 & 1993

(CANADA61997) .

BRNIGRVIYEL

GRNIBLU

e 9

BLKIWHT BIN/ILK BLK/RED

0 1

WICCM BRN/GRY~

VIOI YE' I

WHTIGRN

VIO/YEL BRN/VIO

BLUIBRN/VEL

----+-j

.LU/ RE DI

170

8RN/GRV

I -

BRNIYEL

(EX 1992 6 7993 200 0R . 6 1990 CONVERTIBLE)

BRAKELIGHT I SWITCH

BRNIYEL

DRIVERS DOOR JAMB SWITCH

(19926 1 993 2 DOOR, 6 1994 CONVERT V"'

W/CCM COMPUTER TEMP SENSOR

BRN1 ~

BLK/WHT

TAC-I~ DRIVER'SSEAT RADIO BELT SWITCH BLUI VIO/YEL

I 1 BRN I

GRN/BLU 9 I WIT/ BRN/GFY/YEL

BLU/VIOIWHT

BRN/RED

YEL LEFTFRONT BRAKEPAD SENSOR

BRNI.P Y

BLK/WHT

VIO/WHT BLU/VIO/WHT

10 75

-I

I 18 ` I

BRN

17 ~I 18

I I

GRV/RED PEDIYEL

I I

MULTI FUNCTION CLOCK

YEL

BRN

BAN

G312

BRN

INNER

BRNIVIO ENGINECOOLANT TEMPERATURE SENSOR

BRNIYEL

WHTwHTRG1

MMONE

RIGHT EAR BRAKEPAD SENSOR

I----

W/_I CC M

I I

CHECK CONTROL MODULE 8299 2

WHT/RED

I-- I

----- --

ON-BOARD DISPLAYICOMPUTER

G203

-I

WHT/BLU

I I

BLKIRED

2{ I

REOIVE L

CHIMEMODULE

ELECTRICAL WIRING DIAGRAMS

ELE-167

Instrument Panel

1998 Except 318ti (1 of 2) HOTAT ALLTIMEE

I I LOCK I ACC *

I _START I RUN 1

IGNITION SWITCH

HK ENGINE ICNDEC

IN .

S( )

W GRV/RED

INTERIOR LIGHT STEM S SYSTEM

A14

~~ 7

WHT/VEL

WHT/VIO

BRN/RED

BLUIBLK

1 ifi

GRV

BRN/GR

18 19

BRNIVIO YEL

HOTINACC, RUN AND START

FUSE I ~ F27 L SA ---GRNII VIO

HOTINRUN ANDSTART

FRONT POWER FUSE 1I DISTRIBUTION BOX ~ F23 - J

FUSE ~F46 15A --32Y

BY GRNII BILL I

viol I VEL I I I

I I

viol

GRN

BLU/BRN EXTERIOR LIGHTS SYSTEM 4 BLU/GRN j~ EXTERIOR LIGHTS SYSTEM 5 GRVIBRN TRANSMISSION SYSTEM 6

1 .'f

L------IJ 1 GRNI

HOTINRUN ANDSTART

GF .1 BILL

VEL

DATA LINK CONNECTOR 15Y j

20Y GI

BRNIRED SUPPLEMENTAL RESTRAINTS SYSTEM ENGINE CONTROLS SYSTEM

BRN/GRN

YEL

RED/VEL

10 89-

l 11 J 12

WHT/GRV GRV

0 BODY COMPUTER SYSTEM SVSTEM

- I ANTI-LOCK BRAKES SYSTEM BLU/BPN ANTI- LOCK BRAKES SYSTEM 13 GRNIREO 1~ENGINE CONTROLS SYSTEM 14 BLU/VIO/VEL 15

WHTIGRN

1 16 I 17 18

VIO/VEL

812 B73

BRN/GRN

GRNIBLU

BRN/VEL BRN/VIO

20 B14 B16

GRV/BLK/VEL

BLDIBLK

ANTI-LOCK

BRN/GRV/VEL

BRNIGRY/VEL

BLU/VIO/WHT

BLUIVIOIWH7

i BRAKESSVSTEM

I ~~ I

BLU/ VID/VEL ENGINE COOLANT TEMPERATURE

BFN

DRIVER'S I SEAT ]BELT SJSWITCH

BLUR . DR BILL// ORGI INSTRUMENT CLUSTER 10462 8

I I I

BRN/ I'D BRAKE FLUID LEVELSWITCH

BRNI SPIN

ELE-168 ELECTRICAL WIRING DIAGRAMS

Instrument Panel

1998 Except 318ti (2 of 2) HOT AT ALLTIMES

HOT IN ACC, RUN AND START y FUSE F45

FUSE OIL TEMPERATUR SENSOR

LEFTFRONT BRAKEPAD SENSOR

PARK BRAKE SWITCH

RIGHTREAR BRAKEPAD SENSOR

FRONTPOWER

I DISTRIBUTION 11,

5=____~-5_J

CHECK CONTROL MODULE

30Y

V101 I WHTI

REDII YELI

SREDI

BFI GRNI

NCAI

YELI

vIOf WHT

: . BR I

1 GROUND

3I 3I 3

BANI

BLK/WHT

AUTOMATIC CLIMATE CONTROL MODULE

BLKLKIW T

13J 1

CONVERTIBLETOP CONTROLMODULE

BRN/RED I

BRN/GRN

BLK/WHT

HIPI AMPLIFIER BLK/WHT

;

REDIYEL

i_--I

WIPERIWASHERMODULE I I

BLK/WHT

-_ I

I-- I CRUISE CONTROL MODULE

I I

BLKIWHT

SLK/WHT

RADIO

PINS USED W/ ON-BOARD DISPLAY

EXTERIOR LIGHTS SYSTEM

BLK/RED

BRN/GRN

BLU/RED

WHT/SLU WHT/GRN

3 4

WHT/GRY

5 6

7 B

BLU/BRN/YEL

STARTING/ CHARGINGSYSTEM

GRN/BLU

BLK/GRN GRN/BLU

WHT/BLU

WHTIRED

BRN/GRY

BLK/WHT

EXTERIOR LIGHTS SYSTEM

BRN/GRY/YEL 0 10

BLU/VIO/WHT BLUIBRN/YEL

V11 /WHT

BLU/VIOIWHT

GRY/RED RAN

16 17

RED/YEL

MULTI-FUNCTION CLOCK

BRN/ DAY / YEL

BRN/YEL BRN/BLK BRN/RED

BRN/GRY

GVEL POWER WINDOWS SYSTEM

BRN/ GRY/I YEL

YEL

ELI

SAW YEL

DRIVERS DOOR JAMB BAN t SWITCH

FUELLEVEL SENSOR

FUELTANK SENSORII

" I BAN I 1 G312

104629

ON-BOARD COMPUTER TEMPERATURE

MODULE

R. VEHICLE SPEEDSENSOR

BRN/ORG

3I 3:1

" I SANI 1

G202

BRN

BAN 1I

BAN/

GAS I 1

G203

ELECTRICAL WIRING DIAGRAMS

ELE-169

Instrument Panel 1995-97 318ti (1 of 2) HOTATALLTIMES

START

LOCK

ACC

ACC EXCEPT 1997

GRN

RED/WHT (ORWHT) GRV/RED

BLU/BRN

SLUIGRN

GAY/BAN

B 8

5A -----

14 GN/) 10

HEADLIGHTS SYSTEM INTERIOR LIGHTS SYSTEM EXTERIOR LIGHTS SYSTEM EXTERIOR LIGHTS SYSTEM TRANSMISSION SYSTEM EXTERIOR LIGHTS SYSTEM

GRY

ENGINE CONTROLS SYSTEM

WHT/YEL

WHT/VIO

RED/YEL

-" I

1997ONLY

10 11

SA_ J

2 REO/ YEL

VIO

EXCEPT 1997

RUN

HOTATALLTIMES RRONTPOWER q31 E I DISTRIBUTION BOX

G27

START i

LOCK

RUN

HOTINRUNANDSTART -~ IGNITION ( SWITCH E

RED/YEL RED/YEL WHTIVEL

WHT/VIO

YEL

GRN/BLU

BLK/WHT BRNISLK

LJ A22 SPEEDOMETER

BLU/BLK

V10

8RN/GRN

18 19

BAN/VI0 YEL

BLK

WHT/BLK

RED/YEL

GRN/VIO

BRN/ORG

, 25

SUPPLEMENTAIL RESTRAINTSSYSTEM ECONTROLS NGINECOTROLSSYSTEM

ENGINECONTROLSSYSTEM ENGINECONTROLSSYSTEM I

CONNA 1 WHT/RED WHT/GRN I

TACHOMETER

BLK/RED

B18

/ 2

BLK/WHT

BRN GRN/BLU

B77

; 4

818

6 7

BLU

A20

YEL/8RN

910

BLK/REO

GRY/BLK/YEL

BLU/BRN

GRN/RED

BLU/VIO/YEL

WHT/GRN

VIO/YEL

17 18

BRNIYEL BRN/VIO

21 Cl

',,III GREDUI

~ITI I I 1

II 1

ENGINE CONTROLS SYSTEM (1997 ONLY)

VIOIYEL BRN/YEL BRN/VIO

I I I I I I STARTING/ CHARGINGSYSTEM

BRNIGRN

20 21

pqy (OR BRN)

BLU/BLK

BRN/GRV/YEL

BRN/YEL

N . ~ I BRN - BELT - I SWITCH DRIVER'S SEAT j .BRN

GRY/BLK/YEL 1997 ONLY

ANTI-LOCK BRAKES SYSTEM

W/pqC~ pqy/BLKIVEL (

p202

B RN/GRY/YEL .

BRN/YEL

YEL/WHT

7 8

11 12 CONNC

EXCEPT 1997

RNGR V (OR B(N/G N)

I 3I

j / 7

INSTRUMENT CLUSTER

BRN/GRN OIL

/~ PRESSURE SWITCH 1)NORMAL 2) 0 .2--BAR

NCAI j G202

83364

I PARK BRAKE SWITCH

NCAI

.1L

GROUND

BRN

IGNITION , ,SWITCH

HEADLIGHTS SYSTEM

10I ,

BRN I

81 4

_ BLU/ I BL [

2 SRN /RED

G203

BRN

\ .I L i B

CONN .

BRN/BLK

ANTI-LOCK BRAKES SYSTEM (1997 ONLY) BLU/VIO/YEL

BRN/REO

ANTI-LOCK BRAKES SYSTEM

HEADLIGHTSSVSTEM

24 823 .1

G202

B RN/ NI vio

IBRAKEFLUID LEVEL SWITCH LEVELWITCH

BRN

16 17

ELE-170

ELECTRICAL WIRING DIAGRAMS

Instrument Panel 1995-97 318ti (2 of 2)

HOT IN RUN AND START HOTINACCY,RUNANDSTART r - -- FUSE ) FUSE F23 / F<6 6 GRN( Btu

32 VIO/~ YEL "

DOMPUTER DATA LINES SYSTEM

15~HT/YEL Y 20

FRONT POWER DISTRIBUTIONBOX

WHT/VIO

DATA LINK CONNECTOR

BRNIYEL(ORGRYIYEL) FUELTANK SENSORII

YEL FUELLEVEL SENSOR

WHT/YEL

RED/YEL RED/YEL RED/YEL WHT/YEL WHT/VIO

BRN/RED

BRN/GRY/YEL YEL

DRIVERS C

G312 .Ip

BRNIBLK

BRN

ELK/RED

BLK/WHT

WHT/GRN

12 13

BRN/YEL

RED/YEL IV BRN

EXCEPT 1997

BRN/VIO

WIPER/WASHER SYSTEM

BLK/R

VIO/YEL

S W ITCH

GRN/BLU BLK/WHT

BLKK/=HT

G202

CHIME MODULE (1997)

ENGINE CONTROLSSYSTEM

BRN/YEL 1110

BANIGFY

BLK/WHT

ON-BOARD COMPUTER TEMPSENSOR

BRNIORG

TAC=I

CRUISECONTROL MODULE

1997 ONLY

BRN/GRY/YEL

BRNIRED

REDIYEL

GRY/RED

INTERIOR LIGHTS SYSTEM

BRN

ENGINECONTROLS ~IHTW /BLK SYSTEM '' WHT/YEL coMPUTERDATA WHT/VIO LINESSYSTEM~

BRN/VIO ENGINE OOLANT TEMPERATURE SENSOR

G203

G312

BRN/ RED

r-BR

COMBINATION (SWITCH

BRNIYEL

63365

BRNIOR

GRY/RED

LEFTFRONT BRAKEPAD SENSOR

RIGHT REAR BRAKEPAD SENSOR

B ,

GRY/RED

YEL

VIO/YE L

BOARDCOMPUTER

~u ,

DIGITAL CLOCK

ELECTRICAL WIRING DIAGRAMS

ELE-171

Instrument Panel 1998 318ti (1 of 2) HOTAT ALLTIMES

r ---

I LOCK/ I ACC *

START 8U"

L------

1 2

WHT GRHEADLIGHTSSYSTEM

HOTINRUN ANDSTART

, IGNITION

GRN

SWITCH

INTERIOR LIGHTS SYSTEM

HOTINRUN ANDSTART

FUSE F27 =A ----

HOTINACC, RUNANDSTART USE

USE ~F23 5= ----

By GFN/ BLU

POWER 1 FRONT DISTRIBUTION BOX J

212Y VI01 YEL'

I I

ORN/ VIO

F4B 15=

OF ., BLU

VIO/ YEL

SS BLUIBRN ~I EXTERIORLIGHTSSYSTEM 9 BLU/GRN , EXTERIORLIGHTS SYSTEM

,SUPPLEMENTAL RESTRAINTS SYSTEM

16 GRV ~~ ENGINE CONTROLS SVSTEM 17 BRN/GRN 18

BRN/VIO

YEL

BILK

A IDBS N

ENGINE CONTROLS SYSTEM

FUEL CONSUMPTION METER

B12 ASC.T IND

SRS IND

12 BLU/BRN ~--* gNTI-LOCK BRAKES SYSTEM 13 GRNIRED ENGINECONTROLS SYSTEM 10 BLU/VIO/V EL 1

18~

BN/VIO

15~HT/GRN

DATA LINK CONNECTOR

" =W= TIGR_ J

RNI El

~ } 17WEL 19

FNIGR N

20 21

GRV/BLK/YEL

BLU/BLK

~ ANTI-LOCKBRAKES SYSTEM

7 8

BRN/YEL BRNIBLK BRN/RED

B V O/ I

BYEL I

VIOBYEL I ENGINE COOLANT TEMPERATURE

INSTRUMENT CLUSTER

104580

DRIVER'S

I SEAT

s jSWITCH

(BELT

B V10

BR NI

GRNI

BRN

BRAKEFLUID LEVELSWITCH

ELE-172

ELECTRICAL WIRING DIAGRAMS

Instrument Panel 1998 318ti (2 of 2)

HOTAT ALLTIMES FUSE,DISTRIBUTI,ONBOK

PARK BRAKE SWITCH

LEFTFRONT BRAKEPAD SENSOR

I L_3c5"_J

RIGHTREAR BRAKEPAD SENSOR

RED/I YELI I

GRN/~

BRNIGRN -

NCAt

VELf

VEL

YEL

BRNj

BRN/W XT

I I --

YEL

W IPERIW ASHER MODU LE REDIYEL BRNIWHT

10~I

I I

CRUISE CONTROL MODULE

BLK/WHT

BRN/WHT

BLK/RED

RADIO

RED/VEL BLK/RED

3 2 CHIME MODULE

BRN/RED

~ WHT/VIO 2J COMPUTER DATA ~l WH/YE LINESSYSTEM WHT/BLK 4 ENGINECONTROLS ~, RED/YEL 5

B 7 8

BRNIORG

BRN/YEL

VIO/VEL

BRN/GRY BLK/WHT

VIOIYEL

VIO/YEL

BRN/GRY/YEL

INTERIORLIGHTS SYSTEM

GFYIRED

8 9 10 11 12

BOARDCOMPUTER

BRNIYEL

BRN/GRV

BRN/BLK SRN/RED

BRN/ORG

RED

GRV/ YEL BRN/I RED /

BRN/I BLK

BRN/' BLK / A

YEL I

BRNII YELI

DRIVERS (DOOR I JAMB ' SWITCH

11f

BRN SP VEHICLE EEDSENSOR

FUELLEVEL SENSOR

FUELTANK SENSORII

BRN

G40E 10458 1

ON-BOARD COMPUTER TEMPERATURE SENSOR

10 NCA

COMBINATION

I I I!

I SWITCH

BRN / BFN

G202

INTERIORLIGHTS SYSTEM

BRN/ ORD I 1 G201

REOIVEL

VIO/YEL

BRN/ORG

GRV/RED

2 DIGITAL CLOCK

ELECTRICAL WIRING DIAGRAMS

ELE-173

On-Board Computer 1995-98 318ti

HOT IN ACCY,

HOTATALLTIMES

RUN AND START _____________________ _-_-I

FRONT POWER DISTRIBUTION BOX I I

FUSE F31 5A

Lam___________________

BRN/FiED

2 3 }4

WHT/VIO WHT/YEL WHT/BLK

32Y

RED/YELL

VIO/YEL I

NCA

BRN/ORG

1 -~~RN " -BRN G302 (Z3) G202 (318ti)

COMBINATION SWITCH COMPUTER DATA LINES SYSTEM

10 COMPUTER DATA LINES SYSTEM 10 ENGINE CONTROLS SYSTEM

RED/YEL

FUSE F46 15A

BRN/ORG

0-'201 (Z3) G203 (318ti)

7 8 9 10 11 ON-BOARD COMPUTER

GRY/YEL BRN/GRY BLK/WHT VIO/YEL GRY/RED

INSTRUMENT CLUSTER SYSTEM INSTRUMENT CLUSTER SYSTEM INTERIOR LIGHTS SYSTEM

BRN/GRY

ON-BOARD COMPUTER TEMPERATURE SENSOR

BRN (Z3) G201 !- G203 (318ti) 83951

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-174

On-Board Computer 1992-97 Except 318ti

HOT IN RUN AND START

FUSE F23 5A

FUSE ?F45 7 .5 .

1 FRO NT POW ER BOX

L~___J

IDISTRIBUTION

HOTATALLTIMES _ _ FUS E, AUXILIARY IFUSEBOX F3 5 =-

rI L

HOTATALLTIMES

I L

FUSE, AUXILIARY IFUSEBOX F41

_ 15-

GRNIBLU

VIO/WHT

BRN/GAY

EXTERIOR LIGHTS SYSTEM

BLUIRED

EXTERIOR LIGHTS SYSTEM

BLU/BRN/YEL

INSTRUMENT CLUSTER SYSTEM

BLK/GRN

STARTINGICHARGING SYSTEM

GRNIBLU

WHT/BLU

WARNING SYSTEM

WHT/RED

WARNING SYSTEM

SRN/GRY

BLK/WHT

V10/WHT

1997

INSTRUMENTCLUSTERSYSTEM

BLUIVIO/WH

INSTRUMENT CLUSTER SYSTEM

1. GRYIRED X10Z0 1

INTERIOR LIGHTS SYSTEM

BLK/VIO

BODY COMPUTER SYSTEM

2 3

BLK/BLU

. RN/P

WHT/VIO

WHT/BLK

BODY COMPUTER SYSTEM EXTERIOR LIGHTS SYSTEM

{t COMPUTER DATA LINES SYSTEM ENGINE CONTROLS SYSTEM

WHT/YEL

11, COMPUTER DATA LINES SYSTEM

WNT/GR

INSTRUMENT CLUSTER SYSTEM

ALLEXCEPT1997 14

AIR CONDITIONING SYSTEM

X]97] . ON-BOARD COMPUTER

.FN Z G203

83490

ON-BOARD CGMPUTERTEMP SENSOR y1 BRN'

BRN

1 GROUND

1994-1996

ELECTRICAL WIRING DIAGRAMS

ELE-175

On-Board Computer 1998 Except 318ti FRONT POWER DISTRIBUTION BOX

2 3 4 5

BLU/RED

6 7 8 9 10

BLUJBRN/YEL BLK/GRN

11 12 13 14

GRN/BLU WHT/BLU WHT/RED BRN/GRY BLK/WHT VIO/WHT

15 1

BLU/VIO/WHT GRYJRED

HOTINRUN _ OR START

HOTINRUN OR START

FUSE F23 5A ----

HOTAT ALLTIMES

FUSE ~ F45 7 .5A _--

FUSE ~ F31 5A ---

30Y

GRN/BLU i

VIO/WHT i

RED/YEL

VIO/WHT

RED/YEL

GRN/BLU EXTERIOR LIGHTS SYSTEM

INSTRUMENT CLUSTER SYSTEM STARTING/CHARGING SYSTEM WARNING SYSTEM WARNING SYSTEM INSTRUMENT CLUSTER SYSTEM INSTRUMENT CLUSTER SYSTEM INTERIOR LIGHTS SYSTEM

18 X1070

BLK/GRN

5 6 7

WHT/VIO WHT/BLK

9 10 11 12 13 14

WHT/YEL RED/YEL WHT/GRY

BRN BLK/WHT/YEL

ON-BOARD COMPUTER MODULE 104489

ANTI-THEFT SYSTEM

EXTERIOR LIGHTS SYSTEM COMPUTER DATA LINES SYSTEM ENGINE CONTROLS SYSTEM 10 COMPUTER DATA LINES SYSTEM

10 INSTRUMENT CLUSTER SYSTEM

gIR CONDITIONING SYSTEM

I G203

ON-BOARD COMPUTER TEMPERATURE SENSOR

BRN~''

G203

ELE-176

ELECTRICAL WIRING DIAGRAMS

Body Computer Module 1996-98 318ti

ROTAT ALLTIMES

HOTAT ALLTIMES

374E ID

6~I' // RED/BLU (

(PARTIAL) BODY ELECTRONICS CONTROL MODULE (ZKE IV) ---I 1 BLK I

BLU/GRY

I 3

BRN/VEL

RED/BILK

I)5 1 6

VIO/WHT

17 18 19 176

1 ' 11

I 1,12 I~13 I 14

HOTAT ALL71MES

HOTINACCY, AUNANOSTAR

OA 1FE

25A 11 E

I Y // RED/GRN/VEL (

HOTAT ALLTIMES

6' RED/WHT (

i I RED I

VIO/WHT (

7S'

REOIWNT I

RED I

VIC/WHT

HOTAT ALLTIMES_ _ r---

DOORLOOKS .(7996)

BLU/GRN RED/BLU WHT

DOOR LOCKS DOOR LOCKS

INTERIOR LIGHTS

(START

pOWERWINDOWS POWER WINDOWS

LOOK

RUN

( SWITCH ~IGNITION I

"ACC -- -_ j

I GRN(

11 DOORLOCKS

RED/GRNIYEL

FRONTPOWER DISTRIBUTION BOX

~5 Au

I REDIWHT

BLK/WHT

PDWERWINDOWS

YEL/GRN BAN

GRN

POWER WINDOWS

I X ,3252 I 1

WHT/GRN

1 2

WHT/BRN/VEL

1 3

WHT/GRN/VEL

BLU/REDIYEL

I,5 I)6 17 I B 19

DOOR LOCKS DOORLOCKS (1997,96)

DOOR LOCKS

(PARTIAL) BODY ELECTRONICS CONTROL MODULE (ZKKE IV) _

ANTI-THEFT

. BRN/BLK

EXTERIOR LIGHTS

SUPPLEMENTALRESTRAINTS pOWERWINDOWS

BLK/GRV VEL/GRV

EXTERIORLIGHTS

POWERWINDOWS

1'10 111 I),2 1 )73

WHT/RED

I id

WHTIBLK

WHT/GRY

1 16 17

I1)18

WHT/BLU WHT/RED/VEL

DOORLOCKS DOORLOCKS

(ORGAN/WHT)

119

RED/GRN/VEL

(I997,9B)

120

G AN/R . .

(i99 .I

1,21

DOORLOCKS DOORLOCKS

COMPUTER DATA LINES~~

ANTI-THEFT

COMPUTER OATH LINES

EXTERIOR LIGHTS STARTINGICHARGING

123 124 2 16 I )2B

BLK VEL/BLK

POWERWINDOWS

VIOIBLK

ANTI-THEFT "1

I I I I I I

I )2

BRN/GRV/VEL

(1997,98)

BRN/BLU/YEL

(1997,98)

04 I) 5 1 6

VIO/WHT

BLK7 B LK/WH~

18B

W UIGA

199 110

BLU/GR GRN/BL

(1998)

I~13 1 ) 14

BRN/WHT

(I99fi)

115 1 16

BLU/YEL BLKIREO

(1996) (1996)

BLK/RED

(1996)

BLK/RED

BLK/GRN

I I

I~2o 1'21 1)22 1)23

I I 1 I I)2B L _ _ J)X1326S I~z4

98665

ANTI-THEFT

POWERWINDOWS (1996)

ON-BOARD COMPUTER "1

POWERWINDOWS

I X13253 I1

G~RV/BLK

WHT IVIO

BLK/GRN

01 ANTI-THEFT ANTI-THEFT

POWERWINDOWS POWER WINDOWS POWER WINDOWS POWER WINDOWS POWER WINDOWS

EXTERIORLIGHTS POWERWINDOWS pOWERWINDOWS POYVERWINDOWS POWERTOPS POWER TOPS

BRN/ORG

BAN

BRN

BAN/- I

G207

G201

I I

BLK/GRN

iBYI

(199 6)

BLKIVIO

(1996) (1997,98)

VIO/GRNIYEL

76 ~ I 17 I

RED

X1 9182

EXTERIORLIGHTS

I I I I i I I I I I I I I I

IS O 14CI

DOORLOCKS

1'22

1 t I 2 ~{ I (1990) GRN 3 I VIOIWHT 4 I BRN/ORG 6 I 6 I 7 ~I CI WHTIYEL 98 CI BLU/GRN/VEL 10 II (1996) BRN/BLK/YEL

L ---

i I I I

ELECTRICAL WIRING DIAGRAMS

ELE-177

Body Computer Module 1996-98 Except 318ti

HOTAT ALLTIMES

HOTAT HOTAT HOTAT HOTAT HOT INACCY, ALLTIMES ALLTIMES ALLTIMES ALL TIMES RUN AND START - 2, USE _ FRONT POWER FUSE FUSE FUSE FUSE DISTRIBUTIONBOX '35 E7 5=3--J ----==---L 30 ---1 5A --1== F'

REDIBLU I

RED/GRN/VEL I

RED/WHT I

RED/WHT

RED I

RED/GRN I

RFD!

REDIGRN

7997, 1998 (PARTIAL) BODYELECTRONICS CONTROL MODULE (ZKE IV)

r_1 1 1 i2 7 I' 3

BILK BRN/VEL

(1998)

RED/WHT BLK/WHT

114

YEL/GRN

1 .16

BEN

I l I 72

WHT/GRN

(PARTIAL) BODY ELECTRONICS CONTROL MODULE (ZKE IV)

~DOORLOCKS

YELIGRVRN

POWER WINDOWS III

(1986)

BLK/GRN

(1996)

I I I I

(1997,99)

125

BLK

126

VIO/BLK

12 1 3

BRN/GRV/VEL

POWER WINDOWS

I 15 1 16 1 17 1 18

I I ( I I I I I

ANTI-THEFT

BRNIGRV/VEL(ORGRN/WHT/VEL) BRNIWHT

1~1a I , 14

BLK/WHT

POWERWINDOWS

WHT/GRN BLUIGRN

POWERWINDOWS

GRN/BLU(ORWHT/VEL)

BRN/WHT

POWER WINDOWS POWER WINDOWS

EXTERIOR LIGHTS

BLU/VEL 3LK/RED

POWER WINDOWS POWER WINDOWS

WHT/RED BLK/RED

ANTI THEFT ANTI-THEFT 11 ANTI THEFT POW .RWINDOWS

VIO/WHT

(1997,98)

BLK/GRN

POWERWINDOWS POWERTOPS POWERTOPS

I~20 I) 21 I~2z 1 23 1 24

BRN/ORG

SPIN "

GRY/RED

(1997)

VIOIWHT/VEL

(1997)

I~26 I_ _ J)X 132s4 96672

ANTI-THEFT

BRNIBLU/YEL

I~11

I I

11 POWERWINDOWS 11 POWER WINDOWS 10 DEFOGGED

, EXTERIOR LIGHTS

I X1 .aaBt I 1 BRN/RED/VEL

112

DOORLOCKS

ANTI-THEFT ANTI-THEFT

SPIN I

" BRN/ORG

G203

.203

I I I I I I I I I I I I

W H T/GRN BRN/WHT WHT/VEL

~I 5 lI1

I I

8 9

I WH T/VIO 11 (I BLKIGRN12 I 13 I 1 4 ~I BLK/GRN 15 (I BLK/VIO

VIO/GRN/VEL

RED/GRN (OR RED)

(1996)

I I

6 ~I 7 ,I

(1896)

I -

X1L19Z

ANTI-THEFT

BLK/W HT (OR BLK)

I I I

ANTI-THEFT

DOOR LOCKS

I~2z 123

19 110

ON-BOARDCOMPU7ER

DOORLOCKS

GRN/RED

ANTI-THEFT

DOORLOCKS

120

1 7

COMPUTER DATA LINES4' LINES STARTINGICHARGING

01 OOORLOCKS

I ' 24 VEL/BLK

I I I

FOWERWINDOWS

(1996)

iF POWER WINDOWS

1 17 WHT/RED/VEL I

1 4 I 5 I 1 8

INTERIOR LIGHTS

POWER WINDOWS

1 16 WHT/BLU

I I

GRV/BG

VIO/WHT

COMPUTER DATA LINES

I I 4, I S, I 6 ~I 7 I 1I 9 I 10 I 3

BEN/BLK/V L

BRN/ORG

SUPPLEMENTAL RESTRAINTS POWERWINDOWS

r -

EXTER OR LIGHTS

ANTI-THEFT ~1

X1321 B~1

F OOORLOCKS 10 ANTI-THEFT

I 15 WHT/GRY

I I

WHT/GRN

POWERWINDOWS

DOORLOCKS

114 WHT/BLK

I I

WHT/YEL

POW FWINDOWS

i~ DOORLOCKS

1 7 13 WHT/RED

1 ) 1B 19 RED/GRN/VEL

BLU/GRN BLU/YEL

EXTERIOR LIGHTS

1 10 YELIG 1`11 I ; 12

ELK/GRV

POWERWINDOWS III POWER WINDOWS 1

POWERWINDOWS

I)6 1l6 III '7 SRN/ELK (1997,98) 9

WHT/VEL

POWERWINDOWS

BLKIGRY

WHTIGRN

1 POWERWINDOWS 1 POWERWINDOWS

IF INTERIOR LIGHTS

WHT/BRN/VEL

1%8

BLK/RED

POWERWINDOWS

DOORLOCKS

1 3 WHT/GRN/VEL 1 pI BLU/RED/VEL

BLK/YEL

POWERWINDOWS

1~ XL32

BLK/RED

POWERWINDOWS

~DDOE OCKS

, POWER WINDOWS POWERWINDOWS

BW/GRN

113

1996

I INTERIOR LIGHTS

VIO/WHT

112

VIO/WHT

DOORLOCKS

BLUIGRY

1 1 8 RED/BLU WHT I 9 1 10 REDIGRN/YEL I' 11 Vi0/B LK 7

RED/GRN (OR RED)

I)REOIBLK I)5 1%6

VIO/WHT

I I

I I I I I I

L - J

ELE-178

ELECTRICAL WIRING DIAGRAMS

Warning System : Chimes HOTATALLTIMES r FUSE F31 I 5A

N" BLK/RED I SOU9 TO NE I (SIGNAL XL7 . __ ___ INSTRUMENT CLUSTER

I I

2''X10018

GRN/wr12T

111

1 z }' X14912 GRN/WHT

w Y

1 10 I

I I

HOTINRUNANDSTART 1FRONTPOWER FUSE (DISTRIBUTION BOX F26 10A I

I I

__- X14Z0

ON-BOARD COMPUTE

3 2

X518

m 2

I T

BLU/-

--~1

IN D

3 BLU/YEL.

w 3

---

AUTOMATIC TRANSMISSION RANGE (SWITCH

12 3 -- ~I

YEL EXTERIOR

LIGHTS SYSTEM BLU/YEL (BACK-UP LIGHTS) I X1426 CHIME MODULE

X522

X522 BRN RN rB

68906

* G202

HOTATALLTIMES - - _1 FRONT POWER FUSE [DISTRIBUTION BOX F31 5A I J 2y X70018 RED/ YELL

RED/ YEL

3 ,1. ---------

( I

INSTRUMENT I SOUND I CLUSTER TONE SIGNAL 9

X17

BLK/ RED 2

104758

11 WHT/ RED

X522

1 T X522

BRN

ON-BOARD COMPUTER

-2-G202

~~ I

I MODULE 10

X1070

WHT/ BLU 3~M_7B

CHIME MODULE

ELECTRICAL WIRING DIAGRAMS

ELE-179

Warning System : Chimes HOTATALLTIMES f-1FRONTPOWER I DISTRIBUTION BOX FUSE 5A JX10018 w~ w

' SOUNDS 9 BLK/RED TONE SIGNAL X17 i) INSTRUMENT CLUSTER

o w ¢_ y

1997-98 318ti

J w

X522

ZI ¢~ m I G2021 G302 (31811) (Z3)

CHIME MODULE

ELECTRICAL WIRING DIAGRAMS

ELE-180

Headlights/Foglights 1992-94 (Canada) (1 of 2)

HOT IN RUN AND START

(1992 ONLY) DAYTIME RUNNING LIGHTS CODING DIODE

FRONTPO-R I DISTRIBUTIONBOX

FUSE F25 5A

FUSE F23 SA

YEL/GRY

VEL/GR

VEL/GRY W/CRASH WIG CRASH CONTROLMODULENTROLMODULE VEL/GRY

YELIGRN

EXTERIOR LIGHTS SYSTEM

GRN/VE

> 1992 > G ~ONLY

EXCEPT >~ 199

'EL

I-

HIGH

4 t~

EXCEPT 1994

EXCEPTT 1992

RED'

VEL

1992

YEL

`-RT

.,CRASH I I 9`T(

I MODULE (1992 ONLY)

VEL/GRN'

1992

YEL/GRN (OR GRNIRED) LOW BEAM LIGHT RELAY

YEL

1994 ONLY

RED

5 3T

VEL/GRVt

1992 ONLY

HIGH I COMBINATION BEAMISWITCH SWITCH ,

NORMAL

EXCEPT1992 YELIGRN (ORGRNIRED1I

876

WNT/BLU (OR YEL)

YEL/ BLK

1993 ONLY

4 BRN

L/BL

IINSTRUI HIGH MENT BEAMICLUSTER I I No I(1994 I J ONLY) ```IIllY'' xl& 3~TX]7

6fi

HIGH BEAM LIGHT RELAY

30 -

---------__85

87 2

BEN

BRN

BRNI t_202 BRNI

J'G202

FUSE F12 7 .6=----_---------

W/OOM

FRO NT POWER I DISTRIBUTION FUSE i BOX F29 I 7 .=A - ~

FUSE F30 7.5A 20'1

-_____--------BYx

,0D,7

W/OOOM

1(P

'JL 'J 1m~~ m~ BEAM LIGHT

(OR

YELIBLU (ORVELIGRN) LEFT LOW BEAM LIGHT (EXCEPT ,ss3) 63089

13 12 VEL/BLU YEL/GRN)

12 13 YELIBLU 'DRYELIGRN)

IlJIIROWT

LOW BEAM LIGHT

BEAM LIGHT

(1993)

(EXCEPT 1993) BEN

1 BRN

II BEAM 1 4~ 1 LIGHT

(1993) (EXCEPTT 1993)

YELIBLU (OR VEL/GRN)

REDIWHT

21~---=_________=====47xrn91§

W/OOOM

X1LD2S

FUSE F71 7 .SA

EXCEPT 1994

3: 1

I I I I

a I

I LOW BEAM LIGHT (1993)

B RN

Gill BR N

Gill

ELECTRICAL WIRING DIAGRAMS

ELE-181

Head lights/Foglights 1992-94 (Canada) (2 of 2)

r__T________________________ HOT IN RUN AND START

)

HOT AT ALL TIMES -,FRONT (POWER DISTRIBUTION (BOX

FUSE F22 5A

L__A-________________________J_J

LIGHT SWITCH

I I I

OFF

_ _ 9

P_R_ !

I I

HEAD

(1994) (EXCEPT1994) FOG LIGHT SWITCH RED

(EXCEPT 1994) (1994)

RED RED

YELIBLK

1993 ONLY

_85 G202 ,fly

B-N

SRN

D)WHTT

LIGHT RELAY

876

I FRONTFOG

1994

EXCEPT 1992

RED/W

X1OD1B

I I

FUSE F156A 7 (1994) 15A (EX1994)

1 FRONT I POWER DOISTRIBUTION I '

1u I X1DO18

EXCEPT 1994

u13~ X]DQ15. F SE-1 FI FUSE I F17 IL 10A JI

FRONT POWER DISTRIBUTION BOX

w 8,1 X17 I I

REAR FOG LIGHT SWITCH

FRONT FOG LIGHTS INDICATOR

(INSTRUMENT CLUSTER I I

3YX]Z RIGHT FOG LIGHT

LEFT FOG LIGHT X212 REAR FOG L GHT

'TRUNK ( LIGHT I (1999M (ONLY)

.LY

INSTRUMENT 'CLUSTER I

REAR FOG

NDIICATOR I

SRN '- G202

1 G202

83992

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-182

ELECTRICAL WIRING DIAGRAMS

Headlights/Foglights 1992-94 (USA)

83093H

TINRUNANDSTART c"E

HOTINRUNANDSTART SE

HOTINPUNANDSTART

HOTATALLTIMES FRONT OWER __J

I I I _________-___________t--- J HEAD

GRN/VEL

EXTERIOR -, LIGHTS SYSTEM VE

NORMAL HIGH

YEL

'" OFF PARK

I "

HEAD

VEL/GRN W/ 19920NLV CRASH 1---1 ~ 9 (O R EL) CONTROL YEL 3 MOOULEf

I, /~I ~I" I

YEL

F0 0 LIG HT S WITCH

CRASNCONTROLMODULE

W/O CRAB.1 CONTROL MODULE

HIGH ( COMBINATION SWITCH BEAM SWITCH

>t OFF

PARK

YEL

VEL/GRN (OR YEL)

EL/GRIN (OR VEL)

LOW BEAM LIGHTRELAY BE

87b

(NOTUSED)

HIGH BEAM INDICATOR

I INSTRUMENT I CLUSTER

BRN

876 ,t,

HIGH BEAM LIGHT RELAY

1,1,X16

FRONT FOG LIGHT RELAY

(NOTUSED)

-X39035

FIl 7-E

(EXCEPT199/)

85 9 SRN

1016

¢3

- 1 FRONT FUSEI POWER F75 DISTRIBUTION -.5= J Box

to 1 x+n0+ s.

G202 ----------

5T (7994)

-____-_____

F12 7SAE

--_--_---'Y----------x ts

USE 7SA

1~ X 7003B

FUSE

I I

FRONT POWER DISTRIBUTION BOX

ieYx 1oo17

_8,1, x17 FOG LIGHTS INDICATOR

WIG OCM

W/CCM

I I I

12 YEL/GRN VELIBLU) OR . VEL/GRN (OR VEL/BLUO I

IF-

LEFT LO W BEAM LIGHT (EXCEPT 1993)

JJJL.

LFIGHT BEAM LIGHT (1893)

W/CCM

W/OCCM

I I I

CHECK CONTROL MODULE

2 RIGHT HIGH BEAM LIGHT

(1993) 13YY (EXCEPT1993) VEL/GRN / (OR /' VELIBLU) I

~ VEL/GRN (OR VEL/BLU)2 / 11 RIOHWI~ILOEFT W 81, BEAM LIGHT/ ' LIGHT (EXCEPT 1993) (1993) 1 BRNT SPIN BRN

LEFT HIGH BEAM LIGHT

LEFT FOG LIGHT

RIGHT FOG LIGHT

-L G202

G171

I INSTRUMENT I CLUSTER

ELECTRICAL WIRING DIAGRAMS

ELE-183

Headlights/Foglights 1995 Except 318ti (1 of 2)

HOT IN RUN AND START

-------------FUSE F23 5A

I I

L6r-_________________

YEL

I I I

FLASH

N ORMAL HIGH

`1~

X1DD17

EXTERIOR LIGHTS SYSTEM

/YE

IFRONT POWER I DISTRIBUTION BOX

FUSE F25 5A

YEL

I " RED

HIGH I COMBINATION SWITCH W, TCH I

RED

8 30

LOWBEAM LIGHT RELAY

RED

876 NOTUSED

85 a

YEL

GR ./ RED 8

-IINSTRU(ZHIGHIMENT BEAM CLUSTER IND

I I

JX- V

BEN

NIGH BEAM LIGHT RELAY

4 BRN REOIWH

SPINI 4L G202 3 oD ---------------------------------I I I

FUSE F11

---------

FUSE F12 7 IA

------

X]11086 ----

FUSE F30 7-

FUSE F29 7 .6A _

RIG N7 HIGH BEAM LIGHT

LEFT HIGH BEAM LIGHT

RIGHT LOW BEAM LIGHT

1(fl

BE. 133098

1 BR N

LEFT LOW

SRN

BEAM LIGHT

BEN

dI' G711

FRONT POWER DISTRIBUTION I BOX I

ELE-184

ELECTRICAL WIRING DIAGRAMS

Headlights/Foglights 1995 Except 318ti (2 of 2) HOTINRUNANDSTART

HOTATALLTIMES

(CANADA) (EXCEPT CANADA) FOG LIGHT SWITCH RED

(EXCEPT CANADA) (CANADA)

1 3

RED

~RED RED

8 FRONTFOG LIGHT RELAY

876

G202 + BRN

RED/WHT

ORNN

REDIWHT

)

.CANADA ONLY

CANADA

9),X1((01 --1 FUSE I F15 I 7 .5A Lk__J

EXCEPT CANADA 13

X11! 015 -I FRONT FUSE POWER F17 I DISTRIBUTION 10A , BOX

F- 'F

O I X70m

REAR FOG LIGHT SWITCH I I

B,~XSZ INSTRUMENT 'CLUSTER SFOCNT LIGHICTS IND ATOR I 3 I XjZ

RIGHT FOG LIGHT

(2 DOOR) 3

9 LEFT REAR FOG LIGHT

I I

(LEFT TRUNK I LIGHT (ASSEMBLY

X217

I X31c

4 (2DOOR)1

"L G83099

2 (INSTRUMENT (CLUSTER

REAR FOG LIGHTS INDICATOR I

LEFT

1 t

Tu m

~- G202

FRONT POWER DISTRIBUTION BOX

LIGHT

SPIN

AL G111

>- G202

ELECTRICAL WIRING DIAGRAMS

ELE-185

Headlights/Foglights

1996-97 Except 318ti (1 of 2) HOT IN RUN AND START

HOT IN RUN AND START

FUSE F27 SA

IFRONT POWER I DISTRIBUTION BOX

FUSE F25

II I

LIGHT 5 W ITCH EXCEPT 7997 USA

HE-,-'I ~ OFF II ~PARN I EXCEPT 1997 USA

1N'RMA`J FLASH

r HIGH

SWITCH

RED

HIGH I COMBINATION BEAMI SWITCH

RED YEL LOW BEAM LIGHT RELAY RED

; ---------------

87 ~ 2Y

87b ~ NOTUSED

85 e

YELI

GEN/ RED 6

1,~X1B

HIGH BEAM INDICATOR

I I

HIGH BEAM LIGHT RELAY

(INSTRUMENT (CLUSTER

I BEN

BRN

BE, RED/WHT

BR .

1 3 1

I I

G202

FUSE

X 10076

FUSE

I ?5

w/OCCM

WICCM

__- I

I X10075

W/CCM

FUSE

575A

y 7A_J 2

W/o CCM

RIGHT HIGH BEAM LIGHT

1(fl 88666

[~] RIGHT LOW BEAM LIGHT

LEFT LOW OEAM LIGHT

BEN

1 BRN

LEFT HIGH BEAM LIGHT

BEN

SRN

G111

( FRONT POWER DISTRIBUTION I Box

ELE-186

ELECTRICAL WIRING DIAGRAMS

Headlights/Fog'lights

1996-97 Except 318ti (2 of 2) r

HOT I N RUN AND START

HOT AT ALLTIMES ,FRONT :POWER DISTRIBUTION IBOX

FUSE F22 -_-------------------5A

7y ~C

HEAD

LIGHT SWITCH OFF I

(1998 CANADA) (EXCEPT199BCANADAI FOG LIGHT SWITCH RED

(EXCEPT1996CANADA) (1996 CANADA)

1 3

RED RED

RED

e 86

(EXCEPT 1996CANADA) (1996 CANADA)

.292 AIL

BRN

RED/WHT

BRN

1 1998

2 5

7996 CANADA ONLY

CANADA

RED/WHT

FRONT FOG LIGHT RELAY

-3o

EXCEPT 1996 CANADA

9), X19015 - 1 FUSE F75 I =.s= J L

X. , ,e r I L

SE FUSE F17 I 7 .s= J

FRONT POWER DISTRIBUTION BOX

01 X]0915

FRONT POWER DISTRIBUTION BOX

14YX10016

REAR FOG LIGHT SWITCH

8J~ X17 ~

FRONT FOG LIGHTS INDICATOR

RIGHT FOG LIGHT (2 DOOR) LEFT REAR FOG LIGHT 4 (2 DOOR) 1

LEFT TRUNK I LIGHT IASSEMBLV

j .,

X313 I

2 l. ( INSTRUMENT iCLUSTER

~R FOG LIGHTS INDICATOR I

1 G111 88667

LEFT FOG LIGHT

1_ G2o2

'INSTRUMENT CLUSTER

ELECTRICAL WIRING DIAGRAMS

ELE-187

Headlights/Foglights 1998 Except 318ti HOT IN RUN AND START

I -~ I

HOTINRUNANDSTART

FUSE

HOT IN RUN AND START

FUSE

5A 6

-----_-------._-

-----------_---------0

HOTATALLTIMES

FUSE F~2 IA

FRONT (POWER DISTRIBUTION BOX

________________I

--------------_-------_-_ 4

X 14412

Y GRNIBLU

I I

HEAD

PARK

b OFF

HEAD

4 OFF PARK

2 J.X]P 33A

WIOCOM

WICCM

111, -

036

WIOCCM

-1

~--------I I

FUSE F29 ",A

18Y1441Z 12I

CHECK 13 CONTROL T MODULE

LEFT LOW

RIGHT ~/~J o\ 7 LOW

LIGHT

ILIGHT

~ .~.

LEFT HIGH PAN LIGHT

FUSE F30 7 .5A

FRONT I POWER DISTRIBUTION ( BOX

~ FUSE( F15 7 .6= J

G207

FRONT POWER DISTRIBUTION Box

107 X 1DD1a

IRIGHT /~ /~\~'I HIGH BEAM ~/i'LIGHT '~

v G100 104667

rI I

LEFT FOG LIGHT

RIGHT FOG ~ LIGHT

I I

6,{X12

S ~

FO G NTS ILNIGD I CATOR

INSTRUMENT (CLUSTER

ELE-188

ELECTRICAL WIRING DIAGRAMS

Headlights/Foglights

1995-96 318ti (Canada) (1 of 2) HOT IN RUN AND START

HOT IN RUN AND START

FUSE F23

FRONTFOWER

I DISTRIBUTIONBOX

FUSE F25

X]I+ll1Z

I COMBINATION

NORMAL

FLASH

RED

SWITCH

I I

HIGH

RED

- - - - - - - -- -- -

__J

LOWBEAM LIGHTRELAY RED

HT RED/WHT 1~ X1B (

HIGH BEAM INDICATOR

(INSTRUMENT (CLUSTER

HIGH BEAM LIGHT RELAY

---------

RED/WHT

.L G202 1

X10933

FUSE F11 7 .SA

FUSE F12 7 .5A

__ _________

2'r------------------ AY X1D018

LEFT Low BEAM LIGHT

RIG NT LOW BEAM LIGHT

BRN

83831

1j,X 1-

USE

FUSE F3D 7 .SA

121 7 .5A

__________ ==

20~~---_-__

RIGHT HIGH BEAM LIGHT

_ _J

1BY x1D

(~ LEFT HIGH BEAM LIGHT

S \1

I 1

G111

ROWER DISTRIBUTION

I BOX I

ELECTRICAL WIRING DIAGRAMS

ELE-189

Headlights/Foglights

1995-96 318ti (Canada) (2 of 2) HOT IN RUN AND START

HOT AT ALL TIMES

FOG LIGHT SWITCH

RED

FRONTFOG LIGHT RELAY

- 1 FRONT FUSE POWER -5. I DISTRIBUTION 1DYx10P1H

LEFT FOG LIGHT

m 1

RIGHT FOG LIGHT

INSTRUMENT FRONT I CLUSTER FOG LIGHTS INDICATOR I 3

BRN 1 G202

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-190

ELECTRICAL WIRING DIAGRAMS

Headlights/Foglights 1995-96 318ti (USA)

HOT IN RUN AND START HOT IN RUN ANDSTART RUNANDSTART HOTATALLTIMES ___________________________________T____________-H071- _T__________r__~FRONT I

s '

FUSE F23

FUSE F25 SA

111

FUSE F22 5A

- - - - - - - ---

- - - - - - -

--------------

HEAD

G EHIYEL

t .\ -OFF

HEAD

PARK

ILIGHT I SWITCH

t ~\ OFF PARK

IoY

EXTERIOR . LIGHTS SYSTEM

,-~ 2

Y EL

. _ _ HIGH COMBINAT_ BEAM( SWITCH

N__O RMAL

FOG LIGHT SWITC H

CIE >

RED SWITCH ( FLASH HIGH I 6

I --- -----

'POWER DISTRIBUTION (BOX

RED .

LOW ISHTREM BE LIGLAY

FRONTFOG LIGHT RELAY

(NOT USED)

HIGH BEAM LIGHT RELAY

(NOT USED)

X76

(INSTRUMENT HIGH ( CLUSTER BEAM INDICATOR

BRN

9 j X10D16

_1 FRONT FUSEPOWER F16 DISTRIBUTION 7.5A J BOX

I I

01 X ,00, B. BRN G202 X]9035

1~. XSQg35

I FRONT I

POWER DISTRIBUTION

FUSE

7 .1A

I BOX

7. 5A

-A

3 RIGHT HIGH BEAM HT LIGHT

LEFT HIGH 1IBGHT

2J,2J, LEFT FOG y LIGHT '~ 'EAM

RIGHT FOG LIGHT i

_8A,= _ __ ~

FOG

INDIICATOR

S ¢

BEN

83839

BRN

1 6RNr

4L G202 BRN

INSTRUMENT iCLUSTER

ELECTRICAL WIRING DIAGRAMS

ELE-191

Head lights/Foglights

1997 318ti (Canada) (1 of 2)

3 1 -

X18

(INSTRUMENT (CLUSTER HIGH BEAM INDICATOR I

x3z

--------87

1),

________4yxu~~

LEFT 0

LOW EAM LBGHT

2 L GyHpT T]

REDIWH

-0035 FUSE F12 7 .5A

FUSE F11

870

BRN

BIN BIBRNI

HIGH BEAM LIGHT RELAY

14 - -3B FUSE F 2S --__-___ ______

7_A

FUSE F30 20,1,

x10017-

I IT HIGH 2~

LB GHT

G. ~ 2 BLIGHT

BRN

0111 88825

I POWE IR DISTRIBUTION I Box I

ELE-192

ELECTRICAL WIRING DIAGRAMS

Headlights/Foglights

1997 318ti (Canada) (2 of 2) HOT IN RUN AND START

FUSE F23 13A

HOTATALLTIMES

-I FRONT

FUSE F22 3A

SYX1001Z

IROWER DISTRIBUTION IBox

uYxLDB,.7

G202

r -x 1

__ T7 FOG LIGHT SWITCH

RED :2

-11

cj RED

RED

FRONTFOG TRELAV

RED/WHT

1007E

LEFT FOG LIGHT

RIGHT FOG LIGHT

r I

BRN

88828

e,l~ X I7

IINBTRUMENT FRONT (CLUSTER FOG LIGHTS INDICATOR I

ELECTRICAL WIRING DIAGRAMS

ELE-193

Head lights/Foglights 1997 318ti (USA)

I__ I I

HOT IN RUN AND START

HOTINRUNANDSTPRT

FUSE j

SA3

GRNIBI I .

HOTINRUNANDSTART

HOTATALLTIMES

- FRONT F DISTRIBUTION

FUSE F~

FUSE F2

5 ______________

5A__________IBOX

m w~

EXTERIOR LIGHTS SYSTEM YEL

VEL

II I I

NORMAL FLPSH

HIGH

I II

LIGHT SW I TC H

COMBINATION HIGH BEAMSWITCH SWITCH RED

Bfi

RED

LOW BEAM LIGHTRELAV

(NOT USED)

HIGH BEAM LIGHT RELAY

(NOT USED)

-___________ B7

I FRONTFOG LIGHT RELAY

370

iJ (INSTRUMENT ( CLUSTER HIGH BEAM INDICATOR

(

r1 I I

F71 7 .$A

X10035

1), X

FUSE F30 7 .5A

FRONT POWER DISTRIBUTION SOX

101 X79015

f12 7 .SA ------

BRN SIRN

j),

91 X7001fi - 1 FUSE( F15 7 .5= J

076

USE F29 7 .5A

I II

FRONT I POWER DISTRIBUTION BOX

_ - -----

2D 1

RIGHT SEA . LIGHT

/'~

LEFT

/\ I~J~\/~ SEAM LIGHT

(f) 1Y

~ L GHT

~ LIGHT 1

I I

X3Z Flo LIGHTS INDICATOR

__J

~- G202

38833

(CLUSTER

ELE-194

ELECTRICAL WIRING DIAGRAMS

Exterior Lights

1992-93 (Canada) (1 of 3) HOTATALLTIMES

HOTINRUNANDSTART

-------------FUSE I F3q I 15A

FUSE F23 5A

L -___--______-

(FRONT (POWER DISTRIBUTION (BOX

BYX1ms

RED IBLKIVEL

i~I

(NOTUSED)

CENTRAL LOCKING MODULE

HAZARD FLASHER RELAY

BLUIGRN/YEL

ANTI-THEFT SYSTEM (ANTI-THEFT CONTROL MODULE)

W/O CRASH CONTROLMODULE

BRNIBLKIYEL

BLUIGRN .W/CRASH CONTROLMODULE a

BLUI GRN

4i1_

WHTIBLUIYEL

5 1 . IE~

;. .

1 G2o2

(2 DOOR) 2 LEFT REAR

IPMP

LEFT ITRUNK (LIGHT 'I ASSEMBLY

q (2 DOOR) 1

BEN

G203'Ir

CRASH CONTROL MODULE

SRN

G203 BLUIBR

LEFT FRONT AUXILIARY TURN LIGHT 1 G312

LEFT FRONT TURN M =

LEFT (FRONT I LIGHT (ASSEMBLY

__-_LEFT TURN INDICATOR

INSTRUMENT CLUSTER

XiZ

// \ .-AR . ( /)INDICPTOR

X15 RIGHT

INDICATOR

r I v B (2 DOOR) 5

BE .

6707

RIGHT FRONT TURN M RIGHT REAR TURN -

M-

RIGHT I TRUNK (LIGHT (ASSEMBLY

-- -

RIGHT I FRONT I LIGHT (ASSEMBLY

RIGHT FRONT AUXILIARY TURN LIGHT

ELECTRICAL WIRING DIAGRAMS

ELE-195

Exterior Lights

1992-93 (Canada) (2 of 3) HOT IN RUN AND START ALL TIMES -_____________________-_____________________HOT AT__-7 FRONTPOER use FUSE (DISTRIBUTION 37 OA 10A I Box

HOT AT ALL TIMES

raIFUSE 10A

RE01

1 X100]7_

0019

----- I LIGHT I SWITCH I II

OFF

HEAD

T ' PARK I~ 6 ~~-+,~----77

REO~/WHT

_ _ _

----__

a 13

i-(CODING jJDIODE YEL/GRN

YEl/GRNr

_-________________

IDAVTIME

Ty RUNNING LIGHTS

1_ j VEl1GRNl BIII1 .

4 YEL/GRN

RIGHT PARK LIGHT/LICENSE PLATE LIGHT RELAY

LEFT PARK LIGHT RELAY

I I I

--------LEFT TAIL LIGHT

BRN G203 'Ip- "

I LEFT PONT I FLIGHT

IgSSEMBLV

B RN

I LEFT

TRUNK (LIGHT ASSEMBLY

1 G312

I I

GRV/VEL (zDOOR)

4 (2 DOOR) 1

LEFT PARK LIGHT

LEFT TAIL LIGHT

141 X10018

II I

_------

L-f -

RIGHT TAIL LIGHT

--RIGHT TRUNK LIGHT RIGHT ASSEMBLY TAIL LIGHT

1 G312

I I I I

GRV/VEL

ELE-196 ELECTRICAL WIRING DIAGRAMS

Exterior Lights

1992-93 (Canada) (3 of 3) HOT IN RUN AND START

HOT IN ACCY, RUN ANO START I

[SI FN SE

T15A

-------------------------------r+ (J~

---_-____-__________________-_-_

FUSE,FRONTPOWER DISTRIBUTION , BOX OA

I ` `LLL I 12 XI201Z

>~2o~'ui62i.B

3 o t

W/OCHECICONTROLMODULE

BRAKE LIGHT SWITCH

O AIT

MIT

4 1

W/0 CHECK CONTROL MODULE

2,1,

I I

I AUTOMATIC

REVERSING LIGHT SWITCH

TRANSMISSION

I RANGE I SWITCH I

BLUIYEL

WICHECK CONTROL MODULE AIT ONLY WIOCHECK CONTROL MODULE

351925 ,CHIME ,MODULE

I RIGHT

TRUNK

RIGHT BACK

S (2 DOOR) 5

I LIGHT

(ASSEMBLY LEFT BACK UP LIGHT

1 G312

67490

LIGHT I(ASSEMBLY

ELECTRICAL WIRING DIAGRAMS

ELE-197

Exterior Lights

1992-93 (USA) (1 of 3) HOTATALLTIMES HOT IN RUN AND START I LFRONT FUSE FUSE IROWER F34 F23 DISTRIBUTION I T 16A BA IBOX ___--_-_--_-I X19919.

_ 'X10017

REDIBLKIYEL

LEFT FRONT AUXILIARY TURN LIGHT

BRN

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-198

ELECTRICAL WIRING DIAGRAMS

Exterior Lights

1992-93 (USA) (2 of 3) HOTATALLTIMES I

FUSE 33 10A

HOT AT ALLTIMES

-------------------

FUSE 37 t0A

71FRONTPOWER (DISTRIBUTION BOX

I I

%(00,9

3 -=r

_ - ) --------O FF HEAD

HEAD

OFF

PARK

HEAD

PARK

LIGHT SWITCH

----------------------- I________-______W/O CHECK CONTROLM000LE

W/O CHECK CONTROL MODULE

W/O CHECK CONTROLMODULE W/CHECK CONTROLMODULE

WICHECK CONTROLMODULE

GRV/BLK

INTERIOR LIGHTS SYSTEM

---------~ CHECK CONTROL (MODULE

---------- I_____ ---_ 1~~-- a,r-----D`r--------r-_--T, 2-1 x1075

(2DOOR) B~ S

I I I I

(2 DOOR) B 3

LEFT TAIL LIGHT

(2 DOOR)-~ 7 RIGHT TAIL LIGHT

I I (2000R) 4 2,L

I RIGHT TRUNK I LIGHT I ASSEMBLY

RIGHT TAIL LIGHT

9 (2 DOOR) 5T

___J

.'-. I

LEFT LICENSE PLATE LIGHT

III

BRN

LOCKI

( MODULE

II _ 4 ( xj3QIA

RIGHT LICENS_ PLATE LIGHT

a O

~ GflV/BLK I

FT I LE TRUNK I LIGHT I ASSEMBLY

LEFT TAIL LIGHT

LEFT LICENSE PLATE LIGHT

4 (2 DOOR) 1

2 p RIGHT LICENSE PLATE LIGHT

BRN

m) 1 G312

(2 DOOR) 9~ 3 i _ I I

I ~

4 (2 DOOR) 1

_3J.____ fLEFT LEFT I FRONT PARK I LIGHT L I GNT J ASSEMBLY

t_ G202

87478

LEFT TA IL LIGHT

LEFT TAIL LIGHT

LEFT TRUNK GRY/YEL

IASSEMBLY I

GRV/YEL

(2 DOOR) ' -------

I I I

RIGHT TAIL LIGHT

---~ RIGHT TAIL LIGHT

mI 1 G312

RIGHT TRUNK

I LIGHT I ASSEMBLY I

RIGHT PARK LIGHT

RIGHT ( FRONT (LIGHT IASSEMBLY

ELECTRICAL WIRING DIAGRAMS

ELE-199

Exterior Lights

1992-93 (USA) (3 of 3) HOT INACCV,SUNANDSTART

I FUSE C6 15A

HOTINRUNANDSTART

-------------------------------

FUS~FRONTPOWER 18105%RIBUTION 25 10A I

-------------------------------------- I

X14419

X79R3Z

a 3~

>U 1

BRAKE LIGHT SWITCH

~ 3I A/T

MIT

W/0 CHECK CONTROL MODULE

REVERSING LIGHT j SWITCH

W/O CHECK CONTROL MODULE

2,L,

- W/CHECKCONTROLMODNLE m

107< e~ X_____________ -_______

I I I

CHECK CONTROL (MODULE

~ P~^ R N

AUTOMATIC TRANSMISSION

~1 "3

I RANGE 1 SWITCH I

T1 I I

"--rrrrrr--rrrrrr

___--cc---a

E3 -.

X 14775

m BLU/VEL

BLU/ = T L

RIGHT RIGHT TRUNK I LIGHT BACK UP ASSEMBLY LIGHT~

-/CHECK CONTROL MODULE A/TONLV CONTROL CONTROL MODULE

HIGH LEVEL STOP LIGHT

II I

1 6312

BLU/VEL (2DOOR) 2f 4

I I

-12 DOOR)1 3 2

RIGHT BRAKE LIGHT

RIGHT BACK UP

(RIGHT TRUNK I LIGHT IASSEMBLV

I-------- ------ 11 ", j S (2 DOOR) 5

67479

(2DOOR) 7

I I I I

(2DOOR)B~

(2DOOR) 5~ 5 LEFT TRUNK

LEFT BRAKE LIGHT

_-----_---(2DOOR) 1

LEFT BACK UP LIGHT _ _

I LIGHT

IASSEMBLY

1 X1A2B I CHIME ( MODULE

ELE-200 ELECTRICAL WIRING DIAGRAMS Exterior Lights

1994-96 Except 318ti (Canada) (1 of 3) HOTINRUNANDSTART

FUSE F30 15A

FUSE F23 SP

HOTATALLTIMES

LEFT

I I

RIGHT

(FRONT (POWER DISTRIBUTION IBO%

(COMBINATION TURN SWITCH SIGNPL I SWITCH I ~ 26 " I I 12 (NOT USED) I I

I I

CENTRAL LOCKING MODULE

HAZARD FLASHER RELAY /YEL

BLU LU/GR .

2' -

BRNN/BLK/YEL

W/OCRASH CONTROLMODULE

ANTI THEFT SYSTEM (ANTI-THEFT CONTROL MODULE)

W/CRASH CONTROL MODULE

BLU/GRN WHTHT/BL . . .

INTERIOR LIGHTS SIGHTS

K/VE~L

B.1.

02 .2 ON~ CONTROL - -~O=F -(2DOOR) 2

LEFT REAR

LAMP

(LEFT TRUNK (LIGHT (ASSEMBLY

HAZARD SWITCH

5 fi<

BR 2X

/YEL

_RED18L

4,I -

/BLU

W/CRASH

2:1

MODULE

CRASH CONTROL MODULE

B G- +

(2 DOOR) 1

SPIN

BRN

G203 BLU/BRN

LEFT FRONT AUXILIARY TURN

RIGHT FRONT AUXILIARY TURN LIGHT

1 G312

LEFT FRONT TURN

_LM -

BR \1 G202 83139

I LEFT FRONT ILIGHT (ASSEMBLY

1. G202

1 G312

G111

ELECTRICAL WIRING DIAGRAMS

ELE-201

Exterior Lights

1994-96 Except 318ti (Canada) (2 of 3) HOTATLLTIMES

HOTATALLTIMES

USE

______-__

HOTINRUNANDSTART

USE

FUSE 25 6A

3 18A

Ll-__________ ---______________________ 14Y

e~p/BLU

HOTATALLTIMES ~FRONTPOWER FUSE (DISTRIBUTION 37 BOX 1-

--------------

_________________-

-_J X1DD18

RED/BLU

w.T

LIGHT I SWITCH

DIMMED

LEFT PARK LIGHT RELAY

-----

OT 2

-------------

4 BRNT

BIN BIN G203 'IF- "

W/O CHECK CONTROLMODULE W/OCHECK CONTROLMODULE

W/CHECK CONTROLMODULE

W/O CHECK CONTROLMODULE

\ WICHECK CONTROLMODULE

GRV/VIO

¢ t7 > 11

RIGHTPARK LIGHT/LICENSE PLATELIGHT RELAY

G .11~14

X10]4

INTERIOR LIGHTS SYSTEM

- - - - - - - - - - ---- - - - - - - - - --

(2DOOR) e~ 6 Z"

(2 DOOR)

r_~ 21

-----LEFT TAIL LIGHT

12DOOR) 4~ 7 FIGHT RIGHT TAIL

RIGHT TAIL LIGHT

' RIGHT TRUNK LIGHT

(2DOOR) 5 _ _

4' (2 DOOR) 1

LEFT LICENSE PLATE LIGHT

(LEFT TRUNK LIGHT ASSEMBLY

LEFT TAIL LIGHT

LEFT LICENSE PLATE LIGHT LIGHT

m I I BRN

DIN

O '

\ RIGHT

\1./PLATESE 1Y LIGHT

(2 DOOR) 81 3 ) .-7-_________--LEFT LEFT TAIL LIGHT

r I

(2 DOOR) LEFT PARK LIGHT

I LEFT FRONT (LIGHT (ASSEMBLY

LEFT TAIL LIGHT

TRUNK I LIGHT I ASSEMBLY

1 G312 GRY/YEL

I I I

(2 DOOR) 4~

RIGHT TAIL LIGHT

(z DOOR)

Bt ~

8314 0

RIGHT TRUNK I LIGHT ~ ASSEMBLY I

GRV/YEL

RIGHT PARK LIGHT

RIGHT ( FRONT (LIGHT J ASSEMBLY

ELE-202

ELECTRICAL WIRING DIAGRAMS

Exterior Lights

1994-96 Except 318ti (Canada) (3 of 3) HOT IN ACCV, RUN AND START I

FUSE 46

X10016

HOT IN RUN AND START

------------__---_-------------{FUS 26

BRAKE LIGHT SWITCH

3 m

WIOCHECKCONTROL MODULE

REVERSING LIGHT SWITCH

2,1, I-

._- ._---------

I- W/O CHECK CONTROL MODULE

- WI CHECK CONTROL MODULE

I I

B~ X 1074 _- . . . . .-------

I I

CHECK ( CONTROL I MODULE

I AUTOMATIC

TRANSMISSION

D ----

BLU/VEL

(2000R)

I I I

(2 DOOR) 5 I

(2 DOOR) 6

I I I

LEFT BAC K

2l.

RIGHT BRAKE LIGHT

In~unN'--I RICH, GK HT TRU I LIGHT BACK L, UP ASSEMBLY ~

BY (2 DOOR) 3 '7`

LEFT BRAKE LIGHT

- (2000)A)

I LEFT TRUNK I LIGHT I ASSEMBLY

I gAN . . I SWITCH

I -

1 I

(2 DOOR) 7 I

X14DIZ

~ 3~

BLU( VEL

--1

I W/CHECK CONTROL MODULE

"4~PIT ONLY WIOCHECK CONTROL MODULE

m 2U ZT F- 1-1 HIGH

. 1

LIGHT

__ 4T I (2 DOOR)

1 X7426

SEAL LIGHT

I I

BLUIVEL (2 . .OF)

m Sl.

(2DOOR)

Ply (2 DOOR)

I I m

(2 DOOR) DOOR) 9l., 7)(2 6~ LEFT BRAKE LIGHT

~ LEFT LEFT BACK UP LIGHT

(2 DOOR)

4TT

¢I

1 0312

8314 1

DISTRIBUTION BOX

TRUNK

I LIGHT

(ASSEMBLY I I

(CHIME ( MODU LE

ELECTRICAL WIRING DIAGRAMS

ELE-203

Exterior Lights

1994-96 (USA) & 1997 Except 318ti (1 of 3) HOT AT ALL TIMES I I

FUSE F34 16A

RED/ELK/YEL

HOT IN RUN AND START

(FRONT (ROWER DISTRIBUTION (BOX

FUSE F23 BA

LEFT

RIGHT

(COMBINATION TURN SWITCH SIGNAL I SWITCH I

!__

_____J

i BODY CONTROL MODULE

HAZARD FLASHER RELAY

BRNI .LK/YEL

BLU/GRN/YEL

ANTI-THEFT SYSTEM (ANTI-THEFT CONTROL MODULE)

W/OCRASH CONTROLMODULE

X191B2 82

BLUIBRN WICRASH CONTROLMODULE

BLU/GRN WHTIBL

INTERIOR /' LIGHTS ~ SYSTEM

LEFT REAR TURN LAM=

(2 DOOR) 1

/YEL 1 B

K/YEL RED D/BL 6

j of

(2 DOOR) 2 5

4( l

LEFT I ITRUNK LIGHT (ASSEMBLY

CRASH CONTROL MODULE

BLUIBRN LEFT FRONT AUXILIARY TURN LIGHT 4I Xlfi

LEFT FRONT TURN

--M =

X16.

I LEFT FRONT I LIGHT (ASSEMBLY

X17

(2 DOOR)_BJ.--RIGHT !T/

1 G202

(RIGHT-y--TRUNK

T=RN (ASSEMBLY LAM-J

B (2 DOOR) ¢~

BRN

RIGHT RIGHT FRONT FRONT ILIGH7 TURN (ASSEMBLY LAM= J

I I

RIGHT FRONT AUXILIARY 14~ I TURN LIGHT

¢ I

m .l G312

Wl G111

ELE-204

ELECTRICAL WIRING DIAGRAMS

Exterior Lights

1994-96 (USA) & 1997 Except 318ti (2 of 3)

-----------------------

HOT AT ALL TIMES

rrFUBE 33 10A

FUSE 37 ~ iDA

,FRONTPOWER (DISTRIBUTION B0K

I L l-------------------------A,__J

r ,

-----------------------

______________________LIGHT

( SWITCH I HE-

OFF

HEAD

OFF

PARK

___

____-_______________

HEAD

PARK

________

O >

_1 0

W/O CHECK CONTROL MODULE

WIOCHEOK CONTROL MODULE

W/OCHECK CONTROLMODULE WICHECK CONTROL MODULE

CON W/CHECK TROLMODULE

GRY/BLK Y

GRY/VIO

-------_--~_____--_------- - ~ %107< _________ -----------

-----------------

17 <

-___-2Y----4T

u (2 DOOR)

(2 DOOR)

SJ._ _ _ _

F -(f (

RIGHT TAIL LIGHT

_ RIGHT TAIL LIGHT

RIGHT I TRUNK LIGHT ASSEMBLY

LEFT LICENSE PLATE LIGHT

SRN

CHECK CONTROL (MODULE

oY-________2Y- ____

INTERIOR LIGHTS SYSTEM

(

1Y x,D7s

RIGHT LICENSE PLATE LIGHT GRY/BL

LEFT LICENSE PLATE LIGHT

m > O RIGHT LICENSE PLATE LIGHT

BRN

(2 DOOR) 8

TAIL LIGHT

TAIL LIGHT F

LIGHT ASSEMBLY

GRY/YEL

________4____

- -_

LE FT PARK LIGHT

AG202

8313 7

(2 DOOR) 1 -LEFT I FRONT LIGHT ASSEMBLY

I I

I I I I

GRY/YEL

(2 DOOR) 4 _

--RIGHT TAIL LIGHT

RIGHT TAIL LIGHT

G312

~IRIGHT (TRUNK LIGHT ASSEMBLY

II I

--RIGHT PARK LIGHT

RIGHT FRONT LIGHT (ASSEMBLY

ELE-205

ELECTRICAL WIRING DIAGRAMS

Exterior Lights

1994-96 (USA) & 1997 Except 318ti (3 of 3) HOTINACCY,RUNANDSTART I

I FUSE 46 16A

HOTINRUNANDSTART

-------------------------------+FUS~FRONTPOWER DISTRIBUTION 26 l .A I

___________________________-_-___ 32

XIDDtn

_-I 12

X10017_

0 »i a3T

I !

BRAKE LIGHT ( SWITCH I

_ ZJ 2

WIOCHECKCONTROLMODULE

W/OCHECKCONTROLMODULE

-W/CHECK CONTROL MODULE I -----------------

9 1

---------

A/T

2 I I

X1n74 --------------I CHECK CONTROL IMOOULE

"1 R

-_-__----------- iaY x107

(2DOOR) 2 (2DCOF)1 4 2 ---------_--- (G RIHT 1 RIGHT RIGHT TRUNK BRAKE BACK (LIGHT I LIGHT UP LIGHT IABSEMBLV i j

(2 DOOR)

- - - - - - - -- - - - LEFT BRAKE LIGHT

4 (2 DOOR) 1

LEFT BACK UP LIGHT

m ¢

LEFT TRUNK I LIGHT IABSEMBLV

BLU/ VEL

m ¢I

WICHECK CONTROL MODULE AIT ONLY [WIOCHECK CONTROL MODULE

(2 DOOR)

(2 DOOR) B~

BLUIVEL

(2 DOOR) 78

I AUTOMATIC TRANSMISSION RANGE I SWITCH

X732fi

HIGH LEVEL STOP LIGHT

I I

CHIME MODULE

_____J

1 6312

BLUIVEL

(2DOOR) 2I 4

I I I

RIGHT BRAKE LIGHT

(2DOOR)1 2,

RIGHT BACK UP 1 GHT

RIGHT TRUNK I LIGHT IABSEMBLV

(2 DOOR) 7

(2 DOOR) 6I

(2 DOOR) 6

--------------8 (2 DOOR) B

8313 8

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-206

ELECTRICAL WIRING DIAGRAMS Exterior Lights

1998 Except 318ti (1 of 3) HOTATALLTIMES I

HOT IN RUN AND START

FUSE F 3C 15A

FUSE F23 5A

FRONT 'POWER DISTRIBUTION BOX

Ly ___________----- _-____I mTX1Dniz

8Y X100AS

a ¢ I

RED/BLK/VEL

(NOT 7 USED)

W/OCRASH CONTROLMODULE BLU/BRN .W/CRASH CONTROLMODULE

BLU/GRN

CRASH CONTROL MODULE 1 G203

!_______ UMENT CLUSTER

------------_J 3T=

RIGHT FRONT TURN LAMP

1 (,DOOR) 8 RIGHT REAR TURN LAMP

RIGHT TRUNK 1 LIGHT IASSEMBLV m

- -

86601

1 G100

G202

2 RIGHT FRONT ~TURNIARv TURN LIGHT

(2 DOOR) 5T

G202

I RIGHT I HEACLIGHT

G012

G100

G202

ELECTRICAL WIRING DIAGRAMS

ELE-207

Exterior Lights

1998 Except 318ti (2 of 3) HOT AT ALL TIMES HOT AT ALL TIMES -------------------FRONTPOWER / FUSE FUSE DISTRIBUTION I ... 1OA t0A

I LIGHT

I SWITCH

HEAD

OFF

HEAD

OFF

HEAD

PARKPARK

_----_______---- J W/O CHECK CONTROLMODULE

W/O CHECK CONTROLMODULE W/OCHEJK CONTRO MODULE W/CHECK CONTROLMODULE

W/ HECK CO TROLMODULE

~I I t7 m

GRY/BLK ,

INTERIOR LIGHTS SYSTEM

_-------______-_-----~~ %1074 -----___--------CHECK

W- _______________ -+--

s,~---i2Y----r`1T

___-

-----~~----

CONTROL MODULE

1YXIO75

RIGHT LICENSE PLATE LIGHT

(2 DOOR)

I TA°L LIGHT I L____-__

4 (2DOOR) 1

I I

88602

LEFT PARK LIGHT

I LEFT HEADLIGHT I I

LEFT TAIL LIGHT

I LIGHT J ASSEMBLY I (2 DOOR) 4 __-__----

I I

L__

RIGHT TAIL LIGHT

5``TT'' T (2DOOR) 6'

RIGHT TAIL

RIGHT TRUNK (LIGHT (ASSEMBLY

-~~ (RIGHT RIGHT HEADLIGHT PARK LIGHT

I I

__J

ELE-208

ELECTRICAL WIRING DIAGRAMS

Exterior Lights

1998 Except 318ti (3 of 3) r -5E---_--__------------- ._____-___--------

HOTINACCV,PUNANDSTART

HOTINRUNANDSTART

Lk___--_______-____-_-_________-_-_-_-__--XtDD1e

all >

2 17

1 8~

i -I

323, 328 .M3 3181

I I

ABSCONTROL ODULEI HVDRAULICUNIT

BLIPCONTROL MODULE

I BOX I

X1oDu

15~

FRONTPOWER DISTRIBUTION

FUSE 26 IoA

2 ON-BOARD COMPUTER

! I

~--

10 I

I -I

_ _ _2,1, _ _I

I -I TRA NSMISSION CONTROLMODULE

CRUISE MODULE

CONTROL .

REVERSING LIGHT SWITCH

I I

P R

AUTOMATIC 6M168ION ( RANGE I SWITCH

I ~1

"2 - ~

WICHECK CONTROL MODULE m .

________9~X1074

(CHECK CONTROL (MODULE

! 'S ,

4[ YX 1075.

(2DOOR) 221

(2DOOR) 21

(2 DOOR) 5 8,{,

(2 DOOR) 8 7A,

LEFT BRAKE LIGHT

LEFT BACK UP LIGHT

WICHECK CONTROL MODULE

BLUIYEL

WIOCHECK

RIGHT 'F CONTROL RIGHT RIGHT l 7RUNN ` I BRAKE BACK (LIGHT .HT -, ! LIGHT UP (ASSEMBLY I

(2 D OR) 7 8

BLUIYEL

(2 DOOR) 5~

0 '

AITONLY (EXCEPT 1998)

MODULE

2QT

LEFT TRUNK LIGHT ASSEMBLY

HIGH LEVEL STOP LIGHT

(

1 _

X1476 !CHIME MODULE I (EXCEPT 1998)

4 (2DOOR) 1

(2DOOR) 2~ -

I I ! !

(2DOOR) 1~ 2

RIGHT BRAKE LIGHT

------ (2 DOOR)

(2DOOR) 7I _-

RIGHT ( TRUNK (LIGHT (ASSEMBLY

~ RIGHT BACK UP : LIGH=~ y Y II

I I !

(2DOOR) 6I

(2DOOR) 5 LEFT TRUNK

(LIGHT LEFT :ASSEMBLY BACK UP I LIGHT-_-

LEFT BRAKE LIGHT ---_--_----

4 (2 DOOR) 1

¢1

1 G312 88603

ELECTRICAL WIRING DIAGRAMS

ELE-209

Exterior Lights

1995-98 318ti (1 of 2) HOT AT ALL TIMES I _ I

HOT IN RUN AND START

FUSE F34 1BA

X1DD1n

FRONT (ROWER DISTRIBUTION IBOx

FUSE F23 SA _____ -

O fim l

X]DD17

Y v

RED/BLK/VEL

r7 >

I I

BLU/G RN/VEL S

-- ( COMBINATION S WITCH RIGHT II

LEFT

I-

XL3DZB I -ANTI-THEFT CONTROLMODULE

BRNIBLKIVEL

t,l

BODVELECTRONICS CONTROLMODULE

1 G202

I I I

LEFT REAR TURN LAMP

I LEFT TRUNK (LIGHT IASSEMBLV

___J

h1'

G20 1

CRASH CONTROL MODULE

3 BRN

BRN

G201

ELECTRICAL WIRING DIAGRAMS

ELE-210

Exterior Lights

1995-98 318ti (2 of 2) HOT INACCY,RUNANDSTART HOTATALLTIMES -----_ _-_ _ _ _ _ ._---------------FUSE FUSE I 33 66 I 16A 10A

L 32 O

HOT AT ALL TIMES FRONT POWER FUSE-1(DISTRIBUTION 37 IBOK 10A

_________________________________

X19016

X10016

'IGNITION B WITCH GHT . i 'SWITCH

..~Isrc ~.~.

(OFF

I LIGHT

I -ACC,(

ISWITCH

---OFP

HEAD

OFF

PARK

I !__

HEAD

OFF

PARK

HEAD

PARK

___

___________________ j

18 'I

I12

ABSCONTROL MODULE( HYDRAULIC UNIT

1B,l~

SLIP CONTROL MODULE

RIGHT LICENSE PLATE LIGHT

10,L

CRUISE CONTROL MODULE

TRANSMISSION CONTROL MODULE

(COMBINATION SWITCH

I PARK IIII

I PRKT I

I=1G=T1------LIGHT

1 0404

~~ EXCEPT S 1997,98

3 (1997,96) p~(OTHERS)

-.1,

_ _

4J,

LEFT TRUNK

HIGH

STOPL LIGHT

PARK LIGH7

I I ASSEMBLY ALT.".`-

__J

BRAKE LIGHT

TAIL LIGHT

TAR LIGHT

63662

G404

G100

G404

ASSEMBLY

RIGHT TRUNK BR LIGHT

LIGHT

ASSEM BLY

I I

0 (1997,98) 3~(OTHERS) - - - -. RIGHT RIGHT FRONT VARK I LIGHT LIGHT I ASSEMBLY

ELECTRICAL WIRING DIAGRAMS

Interior Lights/Illumination 1992-93 (1 of 2)

HOT IN RUN AND START

HOTATALLTIMES

USE

GRNIVEL

RED/BLU

GRN/VEL CANADA

GRN/VEL

U .S .A. RED/BLU

I I

I ERONT POWER I DISTRIBUTION BOX

FUSE F37 10A

F22 BA

CANADA

RED/BLU

11~

HEAD

__-_---_-_

LIGHT I SWITCH

~ PARK 1

____

I I

GRY/SLK

L`YJ 4~I' Y11-101N /

---~~-1

RIGHTPAPK LIGHT/LICENSE I PLPTELIGHT RELAY I

EXTERIOR LIGHTS SYSTEM

YEL/GR

VEL/GRN

B 1 GRV/SLK I

GRV/BLK WIPER/ WASHER MODULE I

DAYTIME RUNNING LIGHTS CODING DIODE

BRN t

" SRN

GRV/BLK

G263

I IHKR CONTROL I --I PANEL I

11 1 Xtxtse GRY/RED UNDER HOOP LIGHT

UNDER HOOD LIGHT SWITCH

GRVIRED

GRYIRED I

TRANSMISSION POSITION INDICATOR LIGHT

GRV/RED I

FRONT EAR_~ ~ CIGAR ASHTRAY I Io ( LIGHTER

BRN

RE.

SRN

j G2D3 60633

GRVIRED

~ 22

I k

GRV/REO I

FRONT ( ASHTRAY

I I

GRV/REO I

GRVIRED I

I h\ I

HEATER SWITCH

I I

GRVIRED

I HEATER ( SWITCH

ELE-211

ELE-212

ELECTRICAL WIRING DIAGRAMS Interior

Lights/Illumination

1992-93 (2 of 2) HOT INACCY,RUNANDSTART

HOTATALLTIMES

I 6 RED/WHT

RED/WHT

RED/WHT 2

26 VIO/WHT

.HT I ./ RE N6HRIOR

BRN/WHT

VIO/WHT

VIO/WHT 3

1~I'

BRNIRED I

BRNIRED

VIO/WHT

BRNIRED

MAKEUP RGER'S ® LIGHT

LIGHTIOR

1 3

BAN

VIO/WHT

DRIVER'S

BRN/RED

MIRROR LIGHT

ANTITHEFT SYSTEM

_ . . _ . .. . _

INTERIOR LIGHTS

LIGHT

BAN

READING LIGHTS

VIO/WHT/VEL

OFF

MAKEUP

SWITCH

BAN

SAN

BAN

1 G203

11 X]3914 ACTIVATION OFINTERIOR LIGHTS

------------------------------PASSENGER'S - - - DOOROPEN

REAR DOOROPEN

- - -

X13933 BRNIGRV/YEL~ INSTRUMENT CLUSTER SYSTEM

BRN/GAY/VEL

BRN/BLU/VEL BRN/GRV/VEL ,

I I

ANTITHEFT SYSTEM

BRN/GRV/VEL I

BRNIBLK 1 BRN/BLUIYEL ,

I " I

CENTRAL I LOCKING I MODULE

X'3014

ANTITHEFT SYSTEM

ANTIBRN/BLK I THEFT ~SYSTEM

BRNIBLU/VEL

BRN/BLK / I " BRN/GRY/YEL

BRN/GRV/VEL (2 DOOR)

POWER WINDOWS SYSTEM

I "

68836

j G312

(4 DOOR)

G203

(2 DOOR)

BRN/BLUIYEL (2 DOOR)

BRN/BLU/YEL 2t

DRIVER'S DOOR JAMB SWITCH

BAN

SWITCH

WITCH 1

BAN

BRN/WHT/VEL

---------(DRIVER'S DOORR (OPEN

GI VE

AKEUP

FRONTDOME LIGHT/ MAPREADING ASSEMBLY

CAPACITOR (1993)

TRUNK LIGHT SWITCH

FUSE I POWER F44 I DISTRIBUTION Box 1A B--I

VIO/WHT

EAR

BAN/WHT

REO/WHT

HOT INACCY,RUNANDSTART

5 USE F43 A -----------------

AR7MEN7 ® LIGHT

t I

FUSE F33 10A ------------------------------------

BAN

PASSENGER'S DOOR JAMB SWITCH

1 G310

(4000R)

G203

(2 DOOR)

BAN/BL

POWER WINDOWS SYSTEM

RIGHT REAR DOOR JAMB SWITCH

LEFT REAR DOOR JAMB SWITCH

ELECTRICAL WIRING DIAGRAMS

ELE-213

Interior Lights/Illumination 1994-97 Convertible (1 of 2)

HOT IN RUN AND START

HOTATALLTIMES

FUSE F22 6A

GRN/VEL

U .S.A . GRN/VEL I

LIGHT __-SWITCH I I i

H EAD

OFF PARK

1 T GRV/BLK' WIPER/ WASHER WA MODULE!

(CANADA)

GRV/BLK

6 I

- -

5`( T GRV/BLK I

BRN

121 GRV/BLK

GRYIBLK

GRY/BLK

CASSETTE BOX LIGHT

GRV/BLK

GRV/RED

.FN

4 BRN

GRV/RED I

I I

___-_ GRV/RED / -- GRV/RED I

11X19 164

I_I

y '/ I' l

I ELOECTRONICS ( CONTROL

ABC ISWITDH I (E X 1s94)

! !

13`I/'' X18126 GRV/RED

Y BAN!

IVE

(ZKEI

GRV/RED 5

I I/~' S

I !

! SWITCH gsz.lss4)

I`~

I/94 S

SPACIAL

BRN!

'''~~~```

! I

BRN '

6 }'' BRNf

SPIN

BRN!

CENTRAL WIND POWER ! OW I5WITCH (2 DOOR . IE% .1994)

G302

3302

._* ._____-______ ~ GRY/RED GRV/RED / GRV/RED

I I_I

GRY/RED I

REAR ASHTRAY LIGHT

CHE CONT ROL ( MODULE

UNDER HOOD LIGHT SWITCH

t ____f____ GRYIRED I GRV/RED I GRY/RED I

IHKR CONTROL I PANEL

= G202

I-

2 GRV/RED

GRV/BLK

TED CLIMATE REGULATION CONTROL M OOUE L

GRVIRED I

BLU/GRN I

GRV/BLK !

UNDERHOOD LIGHT

RIGHTPARK LIGHT/LICENSE PLATELIGHT RELAY

G203

SPIN

_ ~~ I fj 5< I ! I

BRNr "

DIMMER

EXTERIOR LIGHTS SYSTEM (TURN/HAZARD LIGHTS)

EXTERIOR LIGHTS SYSTEM

YEL/GRN

I__~______

GRV/BLK

2A,

4 N~ "

YEL16

__________ 7TTT / BR NI

DAYTIME RUNNING LIGHTS CODING DIODE

RED/BLU

I I I

CANADA

RED/BLU

___________

RED/BLU

GRN/YEL

FRONT I POWER I DISTRIBUTION BOX

BE F37 10A

GRV/RED

RIGHT ( SEAT (HEATER !SWITCH

I l I

B~ LEFT j ( SEAT I HEATER SWITCH

EX1994 &1995 .~ -

GRV/RED

GRV/REO

B f LEFT I /~%'\ I REAR gEAR jIWINDOW ! 'SWITCH

FRONT CIGAR LIGHTER LIGHT 2t

FRONT ASHTRAY LIGHT

SAN

SRI, / 6 ..t I - 1SUNROOF !CONTROL I !ASSEMBLY I L _I

8421 2

ELECTRICAL WIRING DIAGRAMS

ELE-214

Interior Lights/Illumination 1994-97 Convertible (2 of 2)

HOT IN ACCY, RUN AND START FUSE -1FRONT POWER IDISTRIBUTIONBOX F43

r LJ 2s~tI'

VIO/WHT)

VIO/WHTI 41

I I

X79182

BODY ELECTRONICS (ZKE IV)

________ _ J y'

81X39182 2fi7XL]251 ,47X13254 BRN/WHT

I I

VIO/BLK

BRN

RED/BLK

REDIBLK

RED/BLK

VIO/BLK

BRNIWHT

VIOIBLKI 1

REDIBLKI

BRNIWHT 2 GLOVE BOX LIGHT

LEFT FRONT FOOTWELL LIGHT

FIGHT

NT ,I FOOTWELL

BRN

VIO/BLK I J

VIOIBLK I 1 M RIGHT TRUNK COMPARTMENT LIGHT

G230

LEFT TRUNK COMPARTMENT LIGHT

BRNIWHTI

VIOIBLK

BRN/WHT

TRUNK LID SWITCH

FRONT DOME LIGHT/ MAP READING ASSEMBLY

BF.I

BRN

BR N

BRN

VIO/WHT

NCA HARD TOP CONNECTOR 2 VIO/WHTI

VIO/WHT DRIVERS MAKEUP R LIGHT

I LIIGHTOR

REO/WHT ER

BRN

SRN I

NCA

PASSENGERS MAKEUP

2 DRIVERS MAKEUP MIRROR SWITCH

V] PASSENGERS MAKEUP MIRROR SWITCH

RED/WHTI

I LIGHT

BRN

1 G203 8421 3

RED/WHT FEAR

G2311

G312

FIGHT FEAR LIGHT

ELECTRICAL WIRING DIAGRAMS

ELE-215

Interior Lights/Illumination 1998 Convertible

HOTINRUN, ACCYANDSTART fFUSE I F73 26 Viol WHT

HOTAT ALLTIMES

HOTAT ALLTIMES ,FRONT POWER (DISTRIBUTION BOX

'''222h~~~ FUSE / F33

xiaoiB

xjoolB

2T )

x1 3252

B RED/ WHT

viol WHT)

RED

RED/ W x141 B2

ED R

1-1

x1Dle2 BODY ELECTRONICS CONTROL MODULE

I (2KE IV)

I ________-

WHT1~4

BLOK1--3

R60K1

BIO~IX13252

VIO/ BLK 1 GLOVE Box LIGHT REOll ELK

RED BLI

LEFT FRONT FOOTWELL LIGHT

FIGHT T FO HTWELL

3 BRN

BRN

BRN/ WHT I

BLK I

BLK

Z G203

LEFT ® RIGHT TRUNK TRUNK COMPARTMENT COMPARTMENT LIGHT LIGHT

BRN/~ WHT

RED/3

BLK,1'II~

viol RL

,J1/I FRONT DOME

BRN/ WHT

MAP TI READING ASSEMBLY

SAW WHT

TRUNK LID SWITCH

SRN

BRN

a BRNI

" VIO/I W HT'

WHT on VERB MIARROPP LIGHT

j DRIVERS MAKEUP MIRROR SWITCH BRN

4 BRN I

VI-It

Viol WHT

.CA

I I

(HARD TOP CONNECTOR 2

NCA

MFIRERGERS

/ / \I LIGHT

I/j

RED/ WHT

RED/ WHT l

I "

PASSENGERS MAKEUP MIRROR SWITCH

SRNT

RED/ WHT LEFT REAR IN RIOR

BRN I

~ // \

RIGHT REAR

I1~/J INTERIOR LIGHT

BRN

BRNI 1 G203

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-216 ELECTRICAL WIRING DIAGRAMS Interior Lights/illumination

1994-97 Except 318ti & Convertible (1 of 2) HOT IN RUN AND START

HOT AT ALL TIMES

FUSE F22 5A

I II

FUSE F37 1 OA

FRONT POWER DISTRIBUTION BOX

DAYTIME RUNNING LIGHTS CODING DIODE

d~I' YELIGRN / "

1~1' YY/ GRY/BLK'

BflN~ WIPER/ WASHER) MODULE(

(CANADA)

-NN

GRV/BLK

BRN

GRV/BLK

1 G203

12 GRV/BL

GRVIBLZ GRVIBKI GRY/BLK

GRVIBLKI

DIMMER

I 2Y 2 GRV/RED

SRN (

EXTERIOR LIGHTS SYSTEM (TURN/HAZARD LIGHTS)

13 GRV/RED

GRY/RED I

_ _" .. GRV/REO (

GRVIRED

r -I I 5

I I I I

HAZARD (SWITCH

OFF

J-1 3 .RN

I I I I J

2 ® TRANSMISSION POSITION INDICATOR LIGHT

BRN

PEAR ASHTRAY LIGHT

BRN /

BRN

FRONT CIGAR LIGHTER LIGHT

CHECK ( CONTROL I MODULE

BODY ( ELECTRONICS ( CONTROL

I _I (ZKE 7 11)

-I

11Y%18154 UNDER HOOD LIGHT SWITCH

%1911

FY/FED

w____1 __ _ _ ~ __- ______ ~ GRV/RED / GRV/RED / GRV/RESJ GRV/RED / GRV/RED GRV/RED GRVIRE6 / GRV/RED I I ,~ ,y RIGHT LEFT7~ LEFT I (SEAT I ( SEAT E%1994 . REAR (HEATER I (HEATER 61995 ~ I( p 1I WINDOW I SWITCH I I$ (SWITCH (SWITCH I I

FRONT ASHTRAY LIGHT

1 _. I

I I

GRY/RIO ~

GRY/flE0 I

9f .pN_ .

.(PASSENGER'S I /T\ POWER (WINDOW ( SWITCH

1 G201

I /~ ,~(RIGHT I1

/(WINDOW

4T / -RN I

( SUNROOF _ SWITCH I

(

1 5

BRN

8345 2

I RADIO

I IHKR CONTROL I PANEL

I-

BRN I BRN (

GRV/RED

INTEGRATED CLIMATE RE aULA710N

(//

] UNDERH000 LIGHT

GRV/REO

.IIlll

I -~ MODOLEL

CASSETTE BOX LIGHT

.RN

BLU/GRN I

GRVISLK4 I

GRV/BL

EXTERIOR LIGHTS SYSTEM

YELIGRN

B I /( ( C' I

5`T //I ' T

SRN I

BRN

1 - G302

I \l~

(DRIVER'S , POWER WINDOW SW IT ( CH

( SUNROOF SWITCH

I 5

I 1

t BRN

1-1 SUNROOF I (CONTROL (ASSEMBLY I l. -I

ELE-217

ELECTRICAL WIRING DIAGRAMS Interior Lights/Illumination 1994-97 Except 318ti & Convertible (2 of 2) I i

HOT INACCY,AUNANDSTART HOT IN ACCY,SUNANDSTART HOTATALLTIMES __ ------------------------------ __---------------FRONT FUSE FUSE ( POWER FUSE ~F43 ~F44 ~F33 (DISTRIBUTION BOX -- T. 1AA~15A -_--__-___-_-------------___ :___-___---------------

BOOY B`~~I/' RED/WHT I

I I 12

ICONTROOLNICS I MODULE (ZKE I V)

28 ```((( /I

VIO/WHT I

VIO/W H7 "

VIOIWHT

VIO/WN7

VIOIWJ

VIO/WHT 3

DRIVER'S MAKEUP MIRROR LIGHT X IS 191)7) RED/WHT

RED/WHT TRUNK COMPARTMENT LIGHT

1 BRN/WHT

PASSENGER'S MAKEUP MIRROR LIGHT (EX, 1997)

READING

41 ANTI-

" BRN/WHT_j THEFT

SYSTEM

OFF

V10/BLK

FRONTDOME LIGHT/ DING ASSEMBLY

DRIVER'S MAKEUP MIRROR SWITCH BRN

PASSENGER'S MAKEUP MIRROR SWITCH

GLOVE - BOX SLIGHT WITCH

BRN

OFF

TRUNK LIGHT SWITCH

BRNIRED 1 l1 LEFT [ RIGHT REAR REAR INTERIOR INTERIOR LIGHT LIGHT

y I

2 2DOOR '

BRNBRN

6DOOR

~I~

RIGHT REAR INTERIOR LIGHT

3L21

" BRN_ - al G310

^BRN

REAR INTERIOR LIGHT

BRN I "

G312

BRN

BRN a1

G312

BRN I

" 'L21

---__--____--------- ---------------_-

ANTI-THEFT SYSTEM

BRN/WHT I

BRN/BLU/YEL I

BRNIGRYIYEL I

BRN/BLU/YEL I -"

ANTI-THEFT BRN/GRYIYEL I SYSTEM 1 "

ANTITHEFT SYSTEM

A, G203

- - - - - _-

_~ I BODY ELECTRONICS I CONTROL -I MODULE (ZKEIV)

BRNIWHT

~" BRNIWHT

I I

1994 LATE PRODUCTION

BRN/WHT / J//~

OTHERS

BRNIWHT / .'/ ~

RIOHTREAR DOOR JAMB SWITCH

RIGHT REAR DOOR CONTACT Y

BRN

1994LATE PRODUCTION BRNIBLU/YEL I

OTHERS

BRN/GRY/YEL BRNIBLK DRIVER'S DOOR JAMB SWITCH

IT " I

PASSENGER'S DOOR JAMB SWITCH

LEFTREAR DOOR JAMB SWITCH

LEFT REAR DOOR CONTACT BRNT

BRN I

SRN I " SPIN

8345 3

I 1

G312

(4DOOR)

G203

(2DOOR)

BRN I

j G310

(4DOOR)

G203

(2DOOR)

G203

ELE-218

ELECTRICAL WIRING DIAGRAMS

Interior Lights/Illumination 1998 Except 318ti & Convertible

NOT AT ALLTIMES _ _

HOT IN RUN, ACCVANDSTART -__---________________________-_________--

NOT IN RUN . ACCYANDSTART

FUSE F43 5A

FUSE F41 15A

FUSE F33 t0A

X10019

x3Do1B

'ol

RED/ WHT

viol

READING LIGHTS

WHT

V10/ WNT DRIVER'S MAKEUP MIRROR LIGHT

WIREAR y READING LIGHTS

OFF

viol

WHT FRONTDOME LIGHT/ MAP READING ASSEMBLY

Xloo1.e

Viol BLK

WHT VI01 WHT

FRONT ( ER (DISTRIBUTION SOX

~` PASSENGER'S /~ MAKEUP VIO/ /\ ~(~~/~MIRROR BILK ~/ LIGHT

BRN'

I~ '~ J,.~~ GLOVE I ~t (BOX

BRN,

LIGHT ./LLl'~l/~C~'/\I~ SWITCH . DRIVER'S MAKEUP MIRROR SWITCH

WHT

RBLK (

RED

['t

BRN

RED/ WHT

REII WHT

RBLK

TRUNK COMPARTMENT LIGHT

RED

LEFT FRONT ROOTWELL LIGHT

BRN/ WHT

BRNI

WHT

RIGHT FRONT FOOTWELL LIGHT

BRN

BFN

REO/ WHT

] PASSENGER'S MAKEUP MIRROR SWITCH

EN4

BRN

BFN

_~ WH0FL 1 F WI READ NGMP RIGHT REAR INTERIOR LIGHT

LEFT REAR INTERIOR LIGHT

BRN

BR N1

F-W/READNIGLMPP

BRN

SRN

G203

G312

G310

ED/ K

12t:-= tx13252.

I I__ 16

------__--=c--___-GCCCC-__--ccc-__ 2 3 1 SI

BRN/I WHT _ _

1 111

I I ~4 I 15

I IS

BRN/WHT /

BRN/GRV/VEL BRN/BLU/VEL B

BRN/I GRV/VEL

BRN/ BLU/VEL

BRN/WHT

/ANTI-

" BRN/GRVIVEL I

WHT

BRN/ WHT

BNf GRVS/VEL I TRUNK LIGHT SWITCH

1 1/ lll~ ~

SWITCH

WHZ l LEFT REAR

RIGHT REAR

SWITCH

CONTACT

G3121

BR"'

.FN I

-FN (2pOOR)

IRI

G2031G310

WH2 I

PASSENGER'S DOOR

tY 0RN'

W/OANTITHEFT

THEFT T(-

_I I

MODULE (ZKEIV)

W/ANTITHEFT

BRN/ I ` WHT

BRN/ I BLK

GRN/ I ` WHT/VEL

WNT I

SBLK// ~

WNT/VEZ I

BRN/WHT "

BLU/VEZ I DRIVER'S DOOR

_ _-------__--

BFNI WHT I

THEFT

INSTRUMENT CLUSTER SYSTEM

L- J = ANTI-THEFT CONTROL MODULE

104823

BODY ELECTRONICS

I CONTROL

,Y ISBN

WHT VE9

RIGHT REAR

LEFT REAR

S4VMOTCH

MICRO SWITCHSWITCHSLID 1Y

[~A

SPIN I

BFN I (4000R)

/' Jll.

BRN Z

CONVERTIBLE TOP

I I

TRUNK I LIO -I RELAY

ELECTRICAL WIRING DIAGRAMS

ELE-219

Interior Lights/Instrument Illumination 1998 Except 318ti & Convertible

HOTINRUNANDSTART

HOTATALLTIMES

FRONT

f POWER I DISTRIBUTION

FUSE -122 - - - - - - -- - - - - - - - - - -- -- -- - - - - - - 5A

I I

FUSE 137 10A - - 14~7'' XUQQjA RED/BLU

aT X19012

BOX

.1' ./V GR

GRNIVEL~ 8

RED/11- I 11

I I

LIGHT SWITCH

I I

HEAD

- - - - - - _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 4.11 .

I _

7 SAN

GRVIBLK

GRY/BL3I GRV/BLK

++l///ll.

DIMMER

CASSETTE BOX LIGHT

Y T/ /

BRN

GRVIBLK I

EXTERIOR LIGHTS (LICENSEPLATE LIGHTS)

GRV/BLK

CHECK

( CONTROL

( MODULE

GRVIBLK 4q

BODY

WIPER/

I ELECTRONICS I

I_I

1 BR N / BR N~ GRVIRED

~GRVIBLK

I WgSHER ( MODULE

( CONTROL

GRVIRED (

I_I (ZKEI IV)

I _I

BRN

G203

G2D2

EXTERIOR LIGHTS SYSTEM (TURN/HAZARD LIGHTS)

BLUIGRN

GRYIRED (

s ."._

I I I I I I I L

GRY/RED (

GRYIRED (

- - ~ iHAZARD

TRANSMISSION POSITION INDICATOR LIGHT

S WITCH

I I I

BRN I

(

GRYIRED (

2,1,

2~.

GRYIRED GEAR SHIFT LEVER INDICATOR

y 1 '

BAN

ASHTRAY LIGHT

1T SAN

GRVIRED (

GRY/RED (

FRONT CIGAR

2 ~ FRONT ~gSHTRAY

LIGHT

1y 1

I~I I I 2~. _REA

(

GFWRED IN/ AUTO CLIMATE CONTROL

W/ .AUTO CLIMATE CONTROL

GRYIRED GRV/RED

BAN

GRVIRED

ABC SWITCH -

%1B

1B I

I I I I ~ j -

.AN

S3 BR N

INSTRUMENT CLUSTER

13I

1 -I

f f

ON-BOARD COMPUTER MODULE

I I I _~

I I I _I

AUTOMATIC CLIMATE CONTROL MODULE

RADIO

I I I _I THERMOSTAT

GRYIRED

GRYIRED (

GRYIRED

GRYIRED (

GRV/RED (

DRIVER'S (POWER (WINDOW ~IswIrcH

I I I

GRV/RED (

GRYIRED (

GRV/RED (

_I Y

IWINDOW

_ - I( DIOOR) (DNDOOR) Y

100822

BRN I

BI RN

I 1

RAN 1 1

G300

G310

SAN

(

GAY/RED (

G300

RIGHT REAR OWER IwINOOw ISW TCH (CDINSOLE)

GRV/PEO

CENTRAL (POWER (WINDOW ISWITCH (2 DOOR)

I I

PASSENGER'S ,~ RIGHT p i/'J`\ ( REAR POWER (WINDOWOWER IswIrCH

GRYIRED

LEFT I ( REAR I IpOWER I t Iwlrvoow S W ITCH ((CONSOLE) ~Y

LEFT ( REAR (POWER IWINDOW SWITCH DOOR) ON DOOR)

I GRYIRED (

GRV/RED

_I eY

I I

CENTRAL LOCKING SWITCH

~TOP i/T\'HIFI I/\~~~~//(SWITCH I I lY SAN

I 1 G203

I I II -

SUNROOF SWITCH

I I I I_ -I CONVERTIBLE TOP ACTUATING SWITCH

ELE-220

ELECTRICAL WIRING DIAGRAMS

Interior Lights/illumination 1995-96 318ti (1 of 2) HOTATALLTIMES

HOTINRUNANDSTART I 1FUSE I F23 I 5A

GRN/BLU

USE F37 10A

I FRONT POWER I DISTRIBUTION BOX

14Y

RED/BLU

GRNIBLU

r__ 2A,

LIGHT

I I . . .. . . . . . . . . . .. I I I I I I I L__ __-___-_______________ _J HEAD

-FN

OFF PARK

GRY/BLK

GRY/RED

WIPER/ I WASHER I MODULE

I I

-I

I I

GRV/BL GRV/BLK GRV/BLK

EXTERIOR LIGHTS SYSTEM

(TELEPHONE EJECT (BOX I

I - ICLIMATE

CONTROL ISWITCH -IIILLUMINATION

I I _

GRV/RED I

GRYIRED

GRY/BLK CASSETTE BOX LIGHT

y~ 1 BRN

2 I_~

I I

BODY / ELECTRONICS I CONTROL ( MOULE D (ZKEIV)

EXTERIOR LIGHTS SYSTEM (TURN/HAZARD LIGHTS) BLUIGRN /

DIGITAL ( CLOCK /

GRYIRED I

(CENTRAL LOCKING I ISWITCH i

I ~

BRN

TRANSMISSION POSITION INDICATOR LIGHT

BRN I

FRONT CIGAR LIGHTER LIGHT

FRONT ASHTRAY LIGHT

INKS CONTROL SWITCH

GRY/RED

GRV/RED I

GAY/RED

( SUNROOF SWITCH i

1 ,1X]9295 (BOARD COMPUTER

y I _I

L~t-' I

BRN

GRV/RED fi I I I I

.FN

G404 8393 3

I RADIO

I__I

GRV/RED

1 HAZARD ISWITCH _I I

BRN I

GRV/RED I

I I

GRV/RED PASSENGER'S (POWER I WINDOW ISWITCH

1--D R IVER9 (POWER I I WINDOW / ISWITCH ~~I

ELECTRICAL WIRING DIAGRAMS

ELE-221

Interior Lights/Illumination 1995-96 318ti (2 of 2)

HOT INACCY,RUNANDSTART USE

HOT INACCY,RUNANDSTART

15A

HOT AT ALL TIMES

2fi

X-Q-

Vi0/BLK~-----------

VIO/WH_-------------- " -

RED/WHTI

REOI

VIOIBLKI

VIO/WHTI

REDIWHTI

RED(

VIOIWHTI

FRONT POWER DISTRIBUTIONBOX

FUSE FUSE -----------------_---~-----I----/ F43 ~ F33 SA . 1DA

I F44

VIO/WHTI

RED/WHTI

HOTATALLTIMES

RED/WHT

GRY/BLK

GRY/BL

12 X13252

VIOIBLK/YELI

MAKEUP MIRROR LIGHT

BOX S LIGHT

2 X101 82

I BOOYELECTRONICS

---_

47X13252

~ 3/

-`j-I

14I X 132

PASSENGER'S MAKEUP PROP

RIGHT TRUNK LIGHT

REDIBLKI

BFN (

. . . . . . .

CONTROLMODULE

GILD

181

AUTO

MANUAL

READING LIGHT

I BRN/WHT

RIGHT {TRUNK L I GHT (ASSEMBLY

B-/-T

(FRONT DOME LIGHT/ MAP READING ASSEMBLY

INTERIO LIGHT v 5 (NOT USED)

BRN/GRYIYEL I

BRN/BLU/YEL

11 X 401 X401 ER'S B ~OOOR ~MAKEUP MIRROR MA IKEUPB LISWGHT M LIGHT OX LIGHT ITCH LIGHT

RS DOOR JAMB SWITCH

2(1245

BR N

BRN

BRN1

" BRN_(

BRN

Z ----_----_----- i 323 .

8393 4

SPIN

BRN

G404

BNGER'S

TRUN LIGHTK SWITCH

JAMB SWITCH

BR-

BRN

1 . G230

2T BRN

SPIN G404

ELE-222

ELECTRICAL WIRING DIAGRAMS Interior Lights/Illumination

1997 318ti (1 of 2)

HOT AT ALL TIMES

HOT IN RUN AND START

I I

1FI1SE FUSE rF23 F37 15A 110A _ _____________________ fiY

147

GRN/BLU I

FRONT I POWER I DISTRIBUTION BOX

RED/BLU

----------~

HEAD

4 OFF PARK

L_-7-----------------BRN I

-~ LIGHT SWITCH

I y

I I I

-----------------

GRV/BLK I

GRY/RED

1 -1 y

BRN

02 (

GRV/BLK I

I I

TELEPHONE EJECT

BOARD COMPUTER 1-1 11 1'10295

ET--

GRV/BL

12~

I-

EXTERIOR LIGHTS SYSTEM

GRV/BLK

2, WIPER/ I WASHER ( MODULE

I I I

-I

BODY I ELECTRONICS ( CONTROL MODULE (2KEIV)

I _ (DIGITAL

( CLOCK

I RA010

I_ I

EXTERIOR LIGHTS SYSTEM (TURN/HAZARD LIGHTS)

-1i HAZARD SWITCH

ON I I I I

TRANSMISSION POSITION INDICATOR LIGHT

WIHEATING CONTROL

OFF

GRV/RED

HEATING& CLIMATE CONTROL

GRVIRED

GRV/RED

4~ BR

I I

BRN I

BFN I

BRN

PASSENGER'S ( SEAT (HEATER SWITCH I I

GRV/R ED I \ I

I I

REAR (DEFOGGER (SWITCH I GRYIPED

GRV/~ RED 2 " J,

1 G203

" ~~ GRY/REfiD

-(SUNROOFL (ASSEMBLY I

BRN

I LIKE I CONTROL I 2_ _ I ( SWITCH ~ CLIMATE I //~~N\\ ( CONTROL I -I I I1 (" /SWITCH ILLUMINATION " I 1T

CLIMATE I ( CONTROL I~IsWITC N (ILLUMINATION

BBS92

Jl/~N GRV/RED(

I I I I

BRN I

GRV/RED

J-G404

GRYIPED

3j ~PASSENGER'S I/~\ ( POWER I(~ JIWINDOW I ISWITCN

3 ~ DRIVER'S (//~~\\ (POWER I1 F- II SWITCH I (SWITCH

ELECTRICAL WIRING DIAGRAMS

ELE-223

Interior Lights/Illumination 1997 318ti (2 of 2)

28 V10/BLKI

VIO/WHT

RED/WHT

X10018

X10260

2 REDI

REDIGRY/YEI.I

VIO/BLKI

VIO/WHTI

REDIWHTI

RED/WHTI

RED

REDIGRY/YE RED/W HOTATALLTIMES

LIGHT i SWITCH

1 GRYIBLK

12 1 X13252 .i

X 18182 BODY I ELECTRONICS (CONTROL IMOOULE J (ZKEIV)

I I

---------4

LIG oXHTS

VIO/BLK/YEL(

[T BRNI

X13252

2 /

I X

MAKEUP LIIIGRORS

LIIGRaogGER

\[/

UNK LIGHT

(ASSEMBLY

RED/BLK

BRN

~ AUTO

{

MANUALL

READING LIGHT

PRINT DOME LIGHT( IMAP READING IA611MILYI

1 m X13025 N CAI I

- 1ANTI-THEFT (CONTROL (MODULE L---( (ALPINE) I I

INTERIOR LIGHT

NCA 1 ,~ X18025

5 (NOTUSED)

BRN/GRY/YEL I

BID-

BRN

PAS5EM MAKEUP

DRIVER MAKEU

X TISW ITCH

LIGHT

~LGHRORGERS

BIN! BON

BIN BRNI _ j---------------i G230

BnN

BRN/WHT/

BRNIBLU/YEL

~SWITCHB 1 1 DOOR

BIN

BRN/WH

JPA511" DOOR

TRUNK LIGHT SWITCH

SWITCHGER'B

SPIN BRNI 1 G404

81,

J- G230

BRN 1 G404

88584

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-224 ELECTRICAL WIRING DIAGRAMS

Interior Lights/Illumination 1998 318ti

HOT IN RUN, ACCYANDSTART

I L__

HOTINRUN, ACCYANDSTART _-7F43E_--- -----_-----_-_--

IF44E__---

HOTAT ALLTIMES

HOTAT

HOT AT

ALLTIMES ALLTT~IMES ---_ -----------/F47E

15-J

-8-_________~B________________________1°-__-__1_____________ 212 X 10018 V10/WH TI

VIO/BLKI

VIC/BLK

VIO/WHT

VIO/WHTI

VIO/WHT

RED/WHT

qED/WHTI

REDI

RED/WHTI

RED

REDIGRY/YELI

HOTATALLTIMES

109 t0

REO/GRYIYELI

DISTRIBUTION BOX

. RED/W

ILIGHT SWITCH

HEAD( II OFF I I PARK -

GLOVE BOX LIGHT

1 GRYIBLK

VIO/BLKIYEL

DRIVER'S MAKEUP MIRROR LIGHT

RED/WHTI

BRNI

Ir I I

REDI

GRY/BLKI

181

X 73252

X10189 BODY (ELECTRONICS (CONTROL IMOOULE (ZKE I V)

PASSENGER'S MAKEUP MIRROR LIGHT

I 4TX 2B2 REDIBLK /

31 X139s4

BRN/GRY/YEL

BRNIBLU/YEL

REDIWHT

RED/BLK

RED/BL3I

RIGHT TRUNK LIGHT

I I

RIGHT FRONT OTWELL PC LIGHT

I TRUNK LIGHT

]ASSEMBLY

--- _ I

BRN/W

L GOTWELL REDIGRYIVELI N

VIOIWHTI

RED/WHT

BRN

RED/BL

BRN/BLU/YEL 3098 "CA/NCA/

VIO/BLK/YEL

READING LIGHT

AUTO

r (

OOMET ILIGHT/ MAP READING ASSEMBLY

ANTI-THEFT CONTROL ( MODULE ( (ALPINE) L - - -

11 W

X13025

BRN/GRY/YEL BRN/GRY/YEL

X491

L.1

NCA( NCA

INTERIOR LIGHT

GLOVE BOX LIGHT SWITCH

BRNI

MAN

INSTRUMENT CLUSTER SYSTEM

BRN

DRIVER'S MAKEUP MIRROR LIGHT

REDIYEL

BRN/WHT/

BRNIGRY/YEL

BRN/WHT

BRN/BLU/YEL TRUNK LIGHT SWITCH

X991 PASSENGER'S MAKEUP MIRROR LIGHT

BRN

1]X12Aa GRIN ]

SPIN

104829

REAR CENTER INTERIOR LIGHT

DRIVER'S DOOR JAMB SWITCH

PASSENGER'S DOOR JAMB SWITCH

BRNI

BRN ]

BRNI

ERIN

BRNI t

G201

G404

BIN

BRN

G201

G404

ELECTRICAL WIRING

Interior

318ti

1998

HOT AT ALL TIMES

FUSE F23 BA

FUSE 137 10A

GRN/BLU i

RED/BLU

I I

ELE-225

Illumination

Lights/Instrument

HOT IN RUN AND START

DIAGRAMS

FRONT POWER DISTRIBUTION BOX

GRNIBLU 5

I I I I

I I

MEAD

~ OFF PARK

LIGHT SWITCH

__ _J SRN

GRYIBLK

" 1

GRV/SLK

BRN ~

-( II !_

II I ! _I

G202

GRV/RED

EXTERIOR GRV/ELK " ~, LIGHTS (LICENSE GRV/BLK LIGHTS) WIPER/ WASHER l MODULE

I I I

BODY ELECTRONICS CONTROL

(DIGITAL CLOCK

I(ZKEIW)

EXTERIOR LIGHTS SYSTEM IT UPNIHAZARD LIGHTS)

G'Y'RED

GRVIRED

GRV/REO

GRV/RED

GRVIRED

GRV/RED

GRV/RED(

TRANSMISSION POSITION INDICATOR ®LIGHT -

HAZARD (SWITCH

I I I (I I I I I I I I L______J ON

_2 II

_ _ 4

( -

I I

4 SRI,

ASC SWITCH

B 2

-- _ - I I i

____

I -

II l

BR . -

BR .

2T IN

l l

G201

iPASSENGER'S POWER (WINDOW IswIrcH

I_ I 4

BRN

10483 0

GRYIRE3_1

I II I

( DRIVER'S POWER (WINDOW (SWITCH

BRN

( PASSENGER'S SEAT (HEATER (SWITCH

I I

GRVIRED

BRN CLIMATE CONTROL SWITCH ILLUMINATION

SPIN

".__-____ + ___-__

CLIMATE (CONTROL /\ SWITCH ~/ (ILLUMINATION Y_ 2

TTT /

GRY/RE3j

I II

( DRIVER'S SEAT (HEATER ISWITOH

BR .

BRN

G302

II I - :I

-CENTRAL LOCKING (SWITCH

GFYI.E .

I I I

G201

JJJ'/I.. 'I, SUNROOF SWITCH

4T BRN 1

B RN

BRN

I BRN I I 1

BRN

G404

BRN 1

FYIRE .

( FOLDING SUNROOF (SWITCH

I I

I I 1

G201

GRV/REBD

'~` I/~ I

GRY/RED '

I II I I--__--~

X 70245

GRYIRED

---- (REAR DEFOGGER (SWITCH GRYIRED

I I I -sp .

INSTRUMENT CLUSTER

X36

I ---I I I

GRVIRED

FRONT CIGAR LIGHTER LIGHT

OF F

SPIN

GRYIRE31

(BOARD COMPUTER

W1 INTEGRATED HEATING & CLIMATE CONTROL

W/HEATING CONTROL 5

I I

RADIO

t______ .-_7______ f

GRV/RED

BLUIGRN

I-I I I

(SUNROOF CONTROL (ASSEMBLY

IHKS (CONTROL (SWITCH

ELE-226

ELECTRICAL WIRING DIAGRAMS

Power Door Locks 1992

HOTATALLTIMES

DATA L INK CONNECTOR

HOT AT ALL TIMES

FUSE F7 5A

HOT IN ACC, RUN AND START

FUSE F35 25A

IFRONTPOWER I DISTRIBUTION BOX

FUSE F43 5A

_______________ ____________ 10 ,x

147X14475

GROUND. ELECTRONICS

PASSENGER'S 12 DGOPOPE N

SUPPLY, 1 33 TERMMAL30 DRIVER'S DOOROPEN DATA

LINK

BRN VIO/WHT

BRN/BLUIYEL RED/GRN

~T BRN/GRV/VEL

WH~

WHT/VIO

;

TKDDIAG DATA LINK VOLTAGE SUPPLY, TERMINALR

7/VEL

(

I~ --1~

RED/GRN RED/GRN

ELK 2

" PASSENGER'S DOOR LOCK SWITCH

ELl1G 1RY 1 LEFTREARDOOR LOCKMOTOR

DRIVE- DOOR HANDLE SW ITCH I ,

COMFORT( RELAY CONTROL

WHT

POWER WINDOWS SYSTEM

VIO/VEL

BLU/GRV

)11 12 '

,13 14

BRN/BLK

WHT/GRY

ifi

WHTIBLK

WHT/BRN/VEL

WHT/GRN

CRASHSIGNAL PASSENGER'S DOORLOCK MOTOR DRIVER' S MOTD00 LOCK ORLOCKED PASSENGER'S DOOR LOCK MOTOR UNLOCKED DRIVER'S DOOR LOCK MOTORUNLOCKED LOCK CONTACT FORARREST TRUNKLOCK MOTOR LOCKED

BRN

.203

BRN

U BLU

:~j

NCP

-/-K

NIA

520

RIGHTREARDOOR LOCKMOTOR INERTIA SWITCH

ELK 2 BLU/GRY 1

WHTIGRN

WHT/GRN'

WHT/BLK

WNT/BLK 5

RED/GRN fi ` DRIYEWS DOOR LOCKMOTOA

WHT 3

HT/BL

BLK 2

TRUNK LOCK MOTOR

WHTIREDIYEL

X25

BLU/RED/YEL

2 i

I I

INSTRUMENT DRIVER'S ICLUSTER DOOR C OPE= -I

WHT/BLK B

I I

BLK

RED/GRN fi

PASSENGER'S DOORLOCK MOTOR

(DRIVER'S STDEPOWER WINDOW MODULE - I(2DOOR)

qE0/GRN/VEL

BRN/BLU/VEL

LOCK/UNLOCK 1 CONTROL 2

WHT/GRN 4

PASSENGER'S I SIDE POWER IWINDOWMODULE C2 DOOR)

7 7

BLU/GRV 7

23 Y

`26 / X13412

BRN/GRV/VEL BRN/BLK BRN/BLU/VEL

r BRNIBLU/VEL

BRN/GRV/VEL

PASSENGER'S DOOR JAMB SWITCH 2

EXTERIOR LIGHTS SYSTEM

BRN/BLK

"rRN B /GRY/YEL

2000R 2

~ PASSENGER'S WINDOW

~ DRIVER' S DOOR JAMB SWITCH

dDOOR 2DOOR ~IDOORHANGLE RIGHT__/ ~`LJ CONTACT 'DOOR 1 1 REARI SWITCH DOOR iI 2 zl

CENTRAL LOCKING MODULE

BRN/BLK

BRNIGRY/VEL

.2DOOR

BB4B3

WHT3

WHT/GRN/VEL

,23

LOCKIUNLOCK CONTROL BATTERY VOLTAGE FOR ZV MOTOR DRI VE GROUNDFOR ZV MOTOR DRIV E

10 WHT/RED j-

TRUNKLOCK MOTORUNLOCKED

INTERFACETO MOD ANTI-THEFT ULE(ALPINEI

WHT 3Y ~-

ILK

REAR ~DOOR

2t. ] DRIVER'S WINDOW RETRACTHIODNLE GO ORAN CONTACT 1 SWITCH

2 DOOR

1f p

LEFT REAR DOOR CONTACT ~". (gDOOR ) /

BRN/ORG

~I CONTi . ( 4 DOG

1` O

ELECTRICAL WIRING DIAGRAMS

ELE-227

Power Door Locks 1993

HOTATALLTIMES

DATA LINK CONNECTOR

HOTATALLTIMES

HOT IN ACC, RUNANDSTART

FUSE F35

USE-

FRONT DISTRIBUTION

VIO/WHT

OTA DATA N VOLTAGE SUPPLY, TERMINAL .

VIO/WHT

DRIVER'SOOOR HANDLESWITCH

COMFORTI RELAVCONTROL

LEFTREARDOOR LOCK MOTOR

11"1110/YEL

WHT 3

WHT

' )

BILK

10 SLUIGRV 11 12

BRN/ RED/YEL

BRN/RED/YEL

ANTI-THEFT SYSTEM

./ BR

NCA

BAN

6_22A4

BRN BAN BRN/BLK 2 CRASH SIGNALI PASSENGER'S 000nLOCKI 15 MOTORLOCKED DRIVER'S 16 D00 LOCK I MOTORLOCKED 17 MO PASSENGER'S DOORLOCK TORUNLOCKED 3 DRIVER'S

DOOR LOCK ' .OT0FUNL0CKED 19 LOCKCONTACT FORARREST 20 MOTRUNKLOCK

BRN

WHTIGBY

RIGHTREARDOOR LOCKMOTOR

DRIVER'SDOOR HANDLESWITCH ., I (W 1PACKAGEONLY)

t G203

WHTIBLK

01111111 01111111

WHT/SRNIVEL WHT/GRN

HT/RED

WH TIGRNIYEL

TORLOCKEDI

- 1INSTRUMENT DRIVER'S ICLUBTER DOOR OPEN -

2a__

PASSENGER'S I SIDEPOWER WINDOW MODULE 112 00001

-- I

DRIVER'S DOOF LOCK MOTOR WHT 3

BLK 2

BLU/GRV 1

r_ ~F~ f

IE,

WHT/BLKS L~ WNT/GRN 4 RE0/GRN B

I -I

DRIVER'S SIDE POWER WINDOW MODULE IIIDOOR)

II 8

PASSENGER'S DOORLOCK MOTOR

4 m m~DOOR BRNIBLK BRN/GRV/YEL

BRN GROUNDFOR 3 INTERIOR LIGHTSI 'GAY/ ILK PARKINGLIGHTI DETECTION

CENTRAL LOCKINGMODULE

PASSENGER'S WINDOW

RETRACTION DOOR HANDLE CONTACT

LEFT

INTERIOR LIGHTS SYSTEM

EXTERIOR LIGHTS SYSTEM

58491

JAMB SWITCH

LEFT REAR DOOR JAMB - SWITCH

G203

ELE-228

ELECTRICAL WIRING DIAGRAMS

Power Door Locks 1994-97 Except 318ti

HOT AT ALL TIMES FUSE F35

I L

la l

2--

RED/GRN/ YEL

INTERIOR LIGHTS SYSTEM

lK } 1 E PWRLKSIG I 22 6LUIGRY VOLT SUPPLY I 4 RE/BL= VOLTSUPPLV I 99 W LOCK SIG ID RED/GRN/YEL GWRSUPPLV I j 11 AUTOINTLTSIG I 15 VBR GND I CONN13252 I 1 WHT/GRN POSTNSIG I 2 W) POSTN SIG I HTIGRN/YEL W ~33 LKSIGTRUNK LID I RN/BLK }7 B CRASHSIG I 13 WHT/RED CENTRAL PRRESTSIG I W LKSIGDRIVERS DOOR I 14

HOT AT ALLTIMES FUSE 1PRONTPOWER DISTRIBUTION BOX F7 55-_J 14 RE ./ GRN

W HT

rr~

ELK 2 BLU/GRY 1 WHT/GRN

WHTIBLK

FEWER

WHT

DRIVERSDOOR LOCK MOTOR

MEN MEN

BLK

BLU/GRY

WHT/GRN

WHT/BLK

RED/GRN

LKSIGPASSENGERS DOOR I LKSIGTRUNKLID I CERNTRALLOCK SIG i

WHT/BLU

PASSENGERSDOOR LOCKMOTOR B LK 2 WHT 3 BLUIGRY 1

H~TIRED 19 CONN 13253

LEFT REAR DOOR LOCK MOTOR

TRUNK GRNIWHT/YEL .CoLID SIG (CONV) I ) 4 REIS(4DOOR) I7CONN13254 W~

I I

I; 9 I 11

DIAG AD I DRIVEAWAVPROTECT I

PWRSUPPLV I

WHT/YEL WHT/VID

WHT/VIGOR BLK/GRN

RED/GRN

CONN10182 RIGHTREARDOOR LOCK MOTOR

BO YELECTRONICS CONTROL MODULE(ZKEIV)

RED/GRN 1 WHT/GRN/YEL 3

WHT/BLU 2

WHT/YEL

WHT 1

DATA LINK CONNECTOR

RED/GRN

DRIVERSDOOR LOCK SWITCH

-L

GRN/WHTIYEL 6 -TIRED WHT/GRN/YEL 4

4 REDIGRN C

TRUNK LID RELAY

PA .SENGERSDO.R LOOKSWITCH

(CONVERTIBLE ONLY)

BLU/GRY GLOVE BOX LOCK MOTOR

GRN/WHT/YEL CONVERTIBLE TOP STORAGE LID

SRN

BRN

WHT

BLU/GRY

G312 WHT/ VIO

BRN/BLK

GAS FILLER LOCK MOTOR

INERTIA SWITCH

WHT

BRN 82987

BRN

~I, G203

L L LOCKING SWITCH (FROM ATE PRODUCTION 1995)

ON-BOARD COMPUTER

RESTRAINT I -,SUPPLEMENTAL SYSTEM CONTROL MODULE I

ELECTRICAL WIRING DIAGRAMS

ELE-229

Power Door Locks 1998 Except 318ti

HOT AT ALLTIMES

HOT AT ALL TIMES FUSE -1 FRONT POWER I DISTRIBUTION BOX F7

FUSE F35

6-__________-_

RED/GRN/' YEL I

5_J

RED/ GRN

WHT 3 BLK 2 1

BLU/GRY

WHT/GRN 4

VIO/BLK INTERIORLIGHT ~SYSTEM `HED/BLK

_ I

ONG 1 .

POSTNSIG I

CRASH SIG I CENTRALAPHESTSIG I

I I

B OOR LOCKMOTOR

"111111

WHT

11~

LKSIGDRIVERSDOOR I LKSIGPASSENGERS DOOR I

Ij I

PASSENGERS DOOR LOCK MOTOR

WHT/GRN WHTIBRN/YEL WHT/GRN/YEL

7 13 14

BRN/BLK

WHT/GRY

WHT/REO WHTIBLK

WHT/BLU IS LKSIGTRUNKLID REDIGRN/YEL CERNTRALLOCKEIG ~% 1D X ta2ca

WHT 3 BLU/GRY 1

BLK 2

~ HT/YBL I B11 WWHT/VIO DIAG I~ 15 BL DRIVEAWAYPROTECT I 16 PWRBUPPL Y I ^ R EDIGHN I

BODY ELECTRONICS CONTROL MODULE (ZKE IV)

M LEFTREARDOOR LOCKMOTOR

/WHT/YEL GR L 44 TRUNK .DOLID SIG (CONVI I RSIG(4DOOR) I X 73s64 CIA .

11-

X13262

2 POSTNSIO I% 3 LKSIGTRUNKLID I

DRIVERS

AUTOINTLTSIG

WHT/BLK RED/GRN

WHT 3 BLU/GRY 1 IlIGHTHEARD OR LOCK MOTOR

FN I 1

BLK

G203

GLOVE BOX LOCK MOTOR

15 WHT/YEL DATALINK~20 WHT/VIO - " CONNECTOR- - - - - -

BLU/GRY BL . GAB FILLER LOCK MOTOR

RED/GRN

BLU/GRY

DRIV ERS D00R LOCKSWITCH

RED/GRN 1 WHT/GRN/YEL 3

WHT/RED

WHT/BLU RED/GRNN

2 ;~

WHT 1

PASSENGERSDOOR LOCKSWITCH

EXCONV

CONY

TRUNKLOCKMOTOR WHT B WHT 5

GRNIWHTIYEL

RED/GRN

CONVERTIBLETOP STORAGE LID MIC ROSWITCH

GRNIWHTIYEL 6 WHTIGRN/YEL 4

I CENTRAL LOCKING SWITCH

104536

IN ELECTRONIC MOBILIZER CONTROLMODULE

SUPPLEMENTAL RESTRAINTSYSTEM CONTROLMODULE

' TRUNK LID RELAY (CONVERTIBLE ONLY)

ELE-230

ELECTRICAL WIRING DIAGRAMS

Power Door Locks 1995-1998 318ti

HOTATALLTIMES HOTATALLTIMES rr -_-_---~ I ---~~~~~~-----------_ -_-,FRONT POWER

HOTATALLTIMES

I L

FUSEF7

FllEFll

5A - -25A ______-_____________ ___ JBox 14 i(X39D3.a " z lnnln QI

DRIVER'S DOOR LOCK SWITCH

PASSENGER'S DOOR LOCK SWITCH

DISTRIBUTION

I CENTRAL I I LOCKING SWITCH II- J] (199fi,97,98) 1Y

REDIGRN/YEL

ELECTRONIC IMMOBILIZER CONTROLMODULE DATA LINK CONNECTOR 16

i~2

I I6 I9

GRV/BLK BRN/ORS

I EXTERIOR LIGHTS

SYSTEM BRN/ORS " ---- " OIPG201

29 y

6 1

WHTIVEL

I I~~ 11 WHT/VIO I B LK/SRN I16

BLU/GRY

WHT

R ED/SRN/YEL

X13252

I 11 I I2

(1995, 96, 97)

WHT/SRN

3z~

WHT/BRN/YEL

3 T/SRN/VEL WH I14

BLUIEED/YEL

I BRNI .LK I~ 3 WHT/RED I7

I I I I I I I I

II14

1996'96 1997 .90

BRN/BLK

BRN B RN - " --- CII, G203

BRN/BLK

INERTIA SWITCH

WHT/BLK

WHT/BLU

119

REOZ

I I 7 WH

/SRN/VEL

L--I

BODY ELECTRONICS CONTROL MODULE

83276

GAS FILLER LOCK MOTOR

I I 16 WHT/GRV I I1fi

(1990)

X311 34 1,

SUPPLEMENTAL RESTRAINTSVSTEM CONTROLMODULEI

I I

ELECTRICAL WIRING DIAGRAMS

ELE-231

Power Windows 1992 318is & 325is

r1 I II I L--------------_-_-_-_________- ---J HOT AT ALL TIMES

HOT AT ALL TIMES

FUSEF14 30A

FRONTPOWER DISTRIBUTION BOX

A Y

DRIVER'S POWER WINDOW SWITCH

PASSENGER'S POWER WINDOW SWITCH

INTERIOR LIGHTS SYSTEM

INTERIOR LIGHTS SYSTEM XB T4o DRIVER'S SIDE POWER WINDOW MODULE

I T

X1B2Z4

. T X9748

(RELAY

VIO/YEL VIO/YEL

B XsTn< BRN/GRYlYEL INSCRLUSTER_ I SRN/GRY/YEL . PASSENGER'S

q---

SIDE POWER WINDOW MODULE

SYSTEM

BRN/BLU/YEL

I II

I I I CENTRAL LOCKING MODULE

BRN/BLU/YEL

92BB

. T

a T X97_44

'~/

1 G202

B TIJAMB SWITCH'S

Y'l

DRIVER'S WINDOW RETRACT ION ~DOOR

11111 BCH GER'S SIR'S ~SWDOOR '

PASSENGER'S DOW

~DOORDLETION ANDLEWI CONTACT CONTACT SWITCH SWITCH 1

BRN

B RN

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-232

ELECTRICAL WIRING DIAGRAMS

Power Windows 1993 3181s & 325is

HOT AT ALL TIMES

fUSEf14 ~ 30A

iO'S FRONTPOWER TRIBUT10NB0X

e Y

.RIVER'S POWER WINDOW SWITCH

PASSENGER'S POWER WINDOW SWITCH

INTERIOR LIGHTS SYSTEM

DRIVER'S SIDE POWER WINDOW MODULE

1 6302

ANTI-THEFT CONTROL MODULE 30

82TR

. T

XBM

BRNIBLU/YEL

sTe4 PASSENGER'S SIDE POWER WINDOW MODULE

I I

INSTRUMENT CLUSTER SYSTEM

BRN/BLU/YEL

BRN/BLU/YEL BRNIGRYIYEL EARLY PRODUCTION

` w

DRIVER'S DOOR 8280

8'~

XST44

lfl

SWITCH

1 2'~

DRIVER'S WINDOW RETRACTION D0 OR HANDLE CONTACT SWITCH BAN

EARLY PRODUCTION

2 '

IDOORENGER'S

~j/TI~~ JAMB I, SWITCH 1~l'J 1

SAN ml

68816

1 G203

T Om

2'~

PASSENGER'S WINDOW RETRACTION DOOR HANDLE CONTACT 1T SWITCH

ELECTRICAL WIRING DIAGRAMS

ELE-233

Power Windows 1992-93 318i & 325i

HO7A7AlL71ME5

HOTATALLTIMES

I FRONTPOWER

I DISTRIBUTION BOX

FUSE F33

DRIVER'S POWER WINDOW SWITCH

COMFORT RELAY

*---AAA

O O

mI gAN G202

POWER I--1 TOPS SYSTEM

B rCOMFDRT~ (IRELAY I CONTROL

VIOIYEL

CENTRAL LOCKING MODULE

REDIBRN

G302

5 AUTOMATIC CUTOUT

LEFT REAR DOOR POWER WINDOW SWITCH (CONSOLE)

3 CHILD PROTECTION O CONTROL (CONSOLE)

,T 2

RIGHT REAR DOOR POWER WINDOW SWITCH (CONSOLE)

1 w ;o O

HoO

REDIBIBIRN R

BAN 1 G302

LEFT REAR WINDOW SWITCH

RIGHT REAR WINDOW SWITCH

RIGHT REAR WINDOW MOTOR

LEFT REAR WINDOW MOTOR

M REDIBRN

PASSENGER'S POWER WINDOW SWITCH

PASSENGER'S WINDOW MOTOR

1 G3 D2

68544

DRIVER'S SIDE POWER WINDOW MODULE

ELE-234

ELECTRICAL WIRING DIAGRAMS

Power Windows

1994-97 Except 318ti (1 of 2) HOT AT ALL_TIMES _

DRIVERS POWER WINDOW MOTOR

FRONTPOWER r~~L, I DISTRIBUTION BOX F14 I / 'U"-1

PASSENGERS POWER WINDOW MOTOR

L 1 3--J

8 RED/ BLU

I I II I~ EDED-' 6LU I%I I I~ I) I I II 12

TERMINAL30H VOLTSUPPLV VOLTSUPPLV POWERSUPPLV MTRSIG MTRSIG

DATASIG

PLUSSUPPLV VOLTSUPPLV

OPEN SIG CLOSESIG OPENSIG CLOSE SIG CHILDPROTECTSIG OATASIG DATA BIG DATA SIG DATA SIG OPEN SIG OPEN SIG OPEN BIG DATASIG(CONV) CLOSESIG(4DOOR)

BLU/GRN /

L W. VEL/GRN

I I I I I I I I I I I I II II

GRN/RED

BLK/WHT ORBLK

VEL/WHT ORYELIBLK

CONN 13253 BRN/GRV/VEL 2 BRNIBLU/VEL

3 0

VIOIWHT

BLK WHT

WHT/GRN

BLUIGRN

10 15

GRN/BLU BLU/VEL

BLK RED

WHT/RED

CONN13254 BLKIRED 1

6RN/RED

BLU/VEL

BLK/YEL

BLKIRED

WHT/GRN . ._. ._

WHT/VEL

BLK/VEL

SLK/RED

]

8 8

WHT/6RN WHT/GRN WHT/VEL RN BLU/GRN BLU/YEL WHT/VEL

DATASIG(OONV) 11 WHT/GRN OPEN SIG (4 DOOR)ICONN13255

BODVELECTRONICS CONTROL MODULE (ZKE IV)

BLK/RED

I I

BLKIRED

BLK/GRV LATE SIG iBLK/G 8 BLU/GRN CLOSE SIG 9 BLU/VEL CLOSES I G 10 WHT/VEL CLOSESIG I

I I

STARTING/CHARGING SYSTEM

CONN 13252 ~ 9 BLK/GRV

REVOLUTIONSIG

DOORSIG

REVOLUTIONSIG

DOORSIG

BLKIGRN

ICONN10182

h 6 BRN/GRV/VEL

BRN/BLU/VEL

ANTI-THEFT CONTROLMODULE

BRN/GRV/YEL

INSTRUMENT CLUSTER SYSTEM

BRN/GRYIV EL DRIVERS DOOR JAME SWITCHH GRNI N " BRN

WHT WHDT 41

+ G203

(CONVERTIBLE) G301

(EX CONVERTIBLE)

GRN/I BLU

SR .

BRN

3I DRIVERS POWER WINDOW SWITCH

CHILD PROTECTION CONTROL

G203 (CONVERTIBLE) ~~, G303

G302

RED

~--l°{°lJ I - ~ ~J ~

s ~I

(E% CONVERTIBLE) 82908

GRN

(6 DOOR ONLY) PASSENGERB DOOR JAMB SWITCH

RED

INTERIOR LIGHTS SYSTEM

PASSENGERS POWER WINDOW SWITCH

7 8 v 10 n 12 13 14

ELECTRICAL WIRING DIAGRAMS

ELE-235

Power Windows

1994-97 Except 318ti (2 of 2) LEFT REAR WINDOW MOTOR

HOTATALLT MES FUSE -1 FRONT POWER I IDISTRIBUTION BOX F19

RIGHT REAR WINDOW )MOTOR

16 RE O/ V10

GRN)

YEL)

RLEDI

WYEL GRY/RED

6 AUTOCLOSE

BLU/GRN

CLOS

I ---i

BLK/RED I Ii 1 OPEN BLU/GRN I 2 I 3 BLK/YEL I I

I I I I I I I I

BLU/RED

WHT/YEL

BRN

BLK/GRY

10 11

BLU/YEL BLK/RED

GRN/RED

WHT/RED

I }--1 I- --I RELAY MODULE

BLK/V L

OFF W0071 AUTOOPEN

SPIN LEFT REAR DOOR (CONSOLE) POWER WINDOW SWITCH (4 DOOR) LEFT REAR POWER WINDOW SWITCH (CONVERTIBLE)

BRN G2 03

BLUIYEL

CLOSE W DO

BILK/RED WHT/RED

BLK/RED

GRN/RED

OFF " .-- 1 EN WDO

AUTOOPEN " I

BLK/RED BLK/YEL BLK/RED WHT/GRN WHT/GRN WHT/YEL SRN

BLK/GRY BLU/GRN

-5 RIGHT REAR DOOR (CONSOLE) POWER WINDOW SWITCH (4 DOOR) REAR POWER WINDOW SWITCH RIGHT (CONVERTIBLE)

BLU/YEL WHT/YEL

CONVERTIBLE

4DOOR

CLOSE OFF

OPEN T

AUTOOPE

AUTOOPEN

LEFTREARDOOR (DOOR) POWER WINDOW SWITCH (4 DOOR ONLY)

GRY/RED

WHT/YEL

3 CLOSE " OFF

WIT/GIN

OPEN AUTOOPEN

I I

AUTOOPEN J.

GROUND +

G302

CENTRALPOWES WINDOW SWITCH (CONVERTIBLE ONLY) 62909

SRN RIGHT REAR DOOR (DOOR) POWER WINDOW SWITCH (4 DOOR ONLY)

ELE-236

ELECTRICAL WIRING DIAGRAMS

Power Windows

1998 Except 3181, 318ti (1 of 2) HOTATALLTIMES USE -1FRONTPOWER DISTRIBUTION BOX F14

f- -T

RED/ : BLU :

I I

I 12 BLKIGRN I X 10182 IIIJWHT VOLT SUPPLY I fi~ BLU/GRN VOLTSUPPLY I j 7 REOIBLU POWERSUPPLY I S} BLK/WHT 13~ MTRSIG I I 14 YEL/GRN MTRSIG %

STARTING/CHARGING SYSTEM

STARTERSIG

I X1]252

I~ )_2_

9 BLKIGRY YELIGRY REVOLUTIONS . I 20 GR /RED DATASIG 23 BLK PLUSSUPPLY 224 YEL/BLK VOLTSUPPLY X13253 2 BRNIGRY/YEL DOORSIG 3 BRNIBLU/YEL DOORSIG B VIO/WHT OPENS IG 7 BLK/WHT CLOSESIG 3 WHTIGRN OPENSIG 9 BLU/GRN CLOSES10 10 GRN/BLU CHILDPROTECTSIG REVOLUTIONSIG

I D I I I I I I I I I 15 DATASIG II DATA SIG DATA SIG

BLU/YEL BLK RED

WHT/RED

II X13254

I I 2 I 3 OPEN SIG I 4 I DATASIG(CONV) I 5 CLOSE BIG (0 DOOR) I 7 DATA SIG I 8 CLOSE S : . I 9 CLOSE SIG I 1

DATASIG

BLU/YEL BLK/RED WHT/RED GRN/RED

BLK/RED

BLK/YEL

OPEN SIG OPENSIG

BLK/YEL

-/RED

BLKIRED WHT/GRN

WHT GRN

WHT/GRN

WHT/YEL

BLKIGRY

1 2 3 4 5

e 7 S 9 1.

BLKIGRY

BLU/GRN

BLU/YEL

BLU/YEL WHT/YE L

CLOSES G

12 13 14

DATASIG(CONV) 11 WHT/GRN OPEN SIG (4 DOOR) i X13255 8 DYELECTRONICS CONTROL MODULE (2KE IV)

B RNIGRY/YEL

h 5 BRN/BLU/YEL

INSTRUMENT CLUSTER SYSTEM

BRN I GRY/YEL

ANTI-THEFT CONTROLMODULE

BRN/GRY/YEL DRIVER'S DOOR JAMB SWITCH

BRN

._EJR-N--

/~ BLU OR'

CHILD PROTECTION CONTROL ~(4DOOR)

BRNIBLU/YEL

BRN

=-N_

BRN

(EX CONVERTIBLE) .203 G312 (CONVERTIBLE)

104529

GREDI

GRN

G312

PASSENGER'S DOOR JAMB SWITCH

WHT : WHT :

: GRIN

O u p

w a

-~ --

u u

DRIVER'S POWER WINDOW SWITCH

j o

INTERIOR LIGHTS SYSTEM ED

PASSENGER'S POWER WINDOW SWITCH

ELECTRICAL WIRING DIAGRAMS

ELE-237

Power Windows

1998 Except 3181, 318ti (2 of 2) HOTATALLTIMES FUSE 1PRONTPOWER IDISTRIBUTIONBO% F1S

LEFT REAR WINDOW MOTOR

RIGHT REAR WINDOW MOTOR

RED/ VIO

GRUNT

ELI

RED)

WVEL GRYIR~T BLU/GRN

I 1 I 2 I 3 I 4 I 5 I B I R I 10 I 11

1 2 3 4 5 B T B 9 10

BILK/RED BLU/GRN

BLK/VE

CLOSE CLO OFFOPEN I

BLK/YEL

AUTOOPEN "

BLU/RED WHT/VEL B RN

OFF

BLKIGRV BLUIYEL BLK/RED

GRN/RED

13 15

WHTIRED RED/VIC

L__-I RELAY MODULE

Ii _

BRN LEFT REAR DOOR (CONSOLE) POWER WINDOW SWITCH (4 DOOR) LEFT REAR POWER WINDOW SWITCH (CONVERTIBLE)

1 SPIN )

BLU/YEL

-[RED WHT/RED

CLOSE CLO OFF OPEN

BLKIR

GRN/RED

I. _

BILK/RED BLK/YEL

AUTOOPEN "

BLK/RED WHT/GRN WHT/GRN WHTIYEL BRN

BLK/GAY BLUIGRN BLUIYEL

RIGHT REAR DOOR (CONSOLE) POWER WINDOW SWITCH (3 DOOR) RIGHT REAR POWER WINDOW SWITCH (CONVERTIBLE)

WHT/YEL

GRVIRED WHT/YEL CLOSET OFF OPEN WHT/GRN

t I I

AUTOOPEN

AUTOOPEN SRN LEFTREARDOOR(DOOR) POWERWINDOWSWITCH 14 DOOR ONLY)

GRV/RED WHT/YEL

1~ CLOSE1 OFF OPEN

WHT/GRN

2 ,

AUTOOPEN

I I

AUTOOPEN

CENTRAL POWER WINDOW SWITCH (CONVERTIBLE ONLY) 104530

RIGHT REAR DOOR (DOOR) POWERWINDOWSWITCH (4 DOOR ONLY)

ELE-238

ELECTRICAL WIRING DIAGRAMS

Power Windows 1995-96 318ti

HOTATALLTIMES (STARTER I

FUSE

1FRONT POWER I DISTRIBUTION BOX

3 DA

DRIVERS POWER WINDOW MOTOR

PASSENGERS POWER WINDOW MOTOR

I I I

q§i

, I 12BLK/GRN ~ CONN10162

I}e h 13 I IJ

REDIBLU BLKIWHT YEL/GRN

CONN13252

BRNIGRY/YEL BRN/BLU/YE VIO/WHT

BLK/WHT

PASSENGERS DOOR JAMB SWITCH

I I CONN13254 I

¢1

ISO

Y ELECTRONICS CONTROL MODULE (ZKE IV)

INT*IOR LIGHTS SYSTEM

t G302 $2951

INT~IOR LIGHTS SYSTEM

DRIVERS POWER WINDOW SWITCH

DRIVERS DOOR JAMB SWITCH

PASSENGERS POWER WINDOW SWITCH

ELECTRICAL WIRING DIAGRAMS Power

ELE-239

Windows

1997 318ti

I hB 1

RED/BLU

SLKjWHT

YELIGRN

CON N 13252

BLK/GRY

YELIGRY

BL}

BLKIWHT

I 24 YEL/BLK I CONN 13253 2

BRNIGRYIYEL BRN/BLU/YEL VIO/WHT

BRN/GRY/YEL

BRN/BLU/YEL 21

I7 BLK/WHT I WHTIGRN I}-II~ I CONN 13254

F-;7 2l1/l

PASSENGERS DOOR JAMB SWITCH

DRIVERS DOOR JAMB SWITCH

BODYELECTRONICS CONTROL MODULE (ZKE IV)

INTERIOR LIGHTS SYSTEM

DRIVERS POWER WINDOW SWITCH

(D I

I I

d .

I -~1 { °1 J L .

PASSENGERS POWER WINDOW SWITCH

G302 BB586

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELECTRICAL WIRING DIAGRAMS

ELE-240

Power Windows

1998 318ti

HOTATALLTIMES

DRIVER'S POWER WINDOW MOTOR

BLKIGRN

0182 B

VIO/WHT

PASSENGER'S POWER WINDOW MOTOR

J-G2Dl

1201

I I I I I I1 I %13252 S

BLK/GRY

YELIGRY

BLK

YELIBLK

I X13253. I I

I I

V~ 10/

I II

BRN/BLD/VEL

I I

BRN/GRY/VEL

DY ELECTRONICS CONTROL MO DOLEECT

INT 'E~RIOR LIGHTS SYSTEM

1 11 11

C I

G302

¢I 1 ~-G404

G201

INT~IOR LIGHTS SYSTEM

DRIVE POWER S WINDOW SWITCH

I .,I

I 1 -'0 {° J L - { -J 1

DRIVER'S I DOOR JAMB SWITCH

104521

PASSENGER'S DOOR JAMB SWITCH

I I

T I I

GER'S POWER WINDOW ( SWITCH

ELECTRICAL WIRING DIAGRAMS

Power Mirrors HOT IN RU=N AND START

IDSOTRBUOTONRBOX

JF24E

LZ IDA 8

GRN/BLK

XLBBLZ

2 MIRROR CONTROL SWITCH LEFT

DRIVER'S

BAN

I------A RIGHT

F-----I-----I DOWN

\PASSENGER'S

WHT

GAN~

WHT

BB K/

WHTI

BLK

GRN

WHT

BBL K/

I NCA

2 NCA

3 NCA

I NCA

2 NCA

NCA

i~ M

DRIVER'S SIDE MIRROR

Y NCA 4 . .

~ PASSENGER'S SIDE MIRROR

NCA 4 ;

BRNI

BAN

1992

BAN

BRNI

BANI y

(COUPEONIV)

G203 88328

HOTINRUTNANDSTART FRONT POWER I /F24E I DBTRIBUOTONRBOX LZIOA

eTxID61T GRN/BLK

MIRROR CONTROL SWITCH LEFT I------1 RIGHT

DRIVER'S

\PASSENGER'S

BAN

WHT' JJJ.

WHTI JJJ

BBLKLull J

NCA

NCAT

NCA

~----{-----I DOWN

3 BLU/ BLK

6 BLU/ GRN

5 BLU/~ WHT

BLUI GRNI

WHTI

BLK/

"CA

NCA

DRIVER'S SIDE MIRROR

N 4A/

BRN~~ ~

~ PASSENGER'S SIDE MIRROR

N 4A'

BRN~~ SAN

1993

BAN

BANI 1 G203 69029

(COUPE ONLY)

ELE-241

ELE-242

ELECTRICAL WIRING DIAGRAMS

Power Mirrors HOT IN RUN AND START FRONTPOWER FUSE -I DISTRIBUTION BOX F24

LZL 2 =J B

xiDDi7

BLU/WHTI 2 MIRROR CONTROL SWITCH LEFT ~- -----1 RIGHT

I-----4-----I DOWN

®RIVER'SPASSENGER'S

G203 83668

HOT IN RUN AND START

FRONTPOWER FUSEIIDISTRIBUTION BOX I F20 L 1-ILJ $YxD®, 7

GRN/BLKI

GRN/BLK

GRN/BLK~ 4

LEFT

----RIGHT

DRIVER'S f

MIRROR CONTROL SWITCH --

DOWN

PASSENGER'S

1995-97 318ti

93705

ELECTRICAL WIRING DIAGRAMS

ELE-243

Power Seats HOTATA_LL_TIM_E_S ________HO_TAT_AL_LT_IMES IFFUSE FRONT POWER ~~~jjj`` FUSE I DISTRIBUTION BOX F5 'F40 30A - J ________ _ 10

XLDQLS

20YXI0018

RED/BLK

RED/VEL 5 SEATBACK

rnm

BACK

HEIGHT

FRONT

rnm

BACK FRONT

GRNIVIOf BLK/VIOTBLUIGRYTVIOIGRYI 1-

__2~

__21

GANT-

BLKT

GLUT-

VIOT

DRIVER'S SEATBACK RECLINERMOTOR

POSITION

m~l

GRN/YEL( BLK/YEL' VIO/REDI BLU/REDTBRNrSRNAI __2~

BLKT

V11 '

GRN' 7'-

DRIVER'S SEAT HEIGHT MOTOR

G312

BLOT

DRIVER'S SEAT DRIVER S SEAT MOVEMENTMOTOR CUSHION TILT MOTOR

RED/ BL 5jJK SEATBACK

BACK I

HEIGHT

POSITION

FRONT

1993

PASSENGER'S SEAT, SEAT CONTROL SWITCH

CUSHIONTILT

BACK FRONT

yyy

BLK/VI

DRIVER'S SEAT, (SEAT CONTROL SWITCH

CUSHION TILT

RN/VOBLUIGRYT VIO/GRYBLK/YEL

GRN/YE41BLU/RED

I v

R IOp IeRN

BAN G203

BLK I

GRN I

BLU I

VIO

BILK

-RN

BLU

(2 DOOR) G310

VIO

(4 DOOR) PASSENGER'SSEATBACWASSENGER'SSEAT RECLINER MOTOR HEIGHT MOTOR

PASSENGER'SSEATPASSENGER'SSEAT MOVEMENT MOTORCUSHIONTILT MOTOR

88740

HOTATALL_TIM_ES __

HOTATALLTIM_ES_ 5F-USE ~FRONTPOWER +++FFUSE , F5 i DISTRIBUTION BOX F40 L _Z______________t30A____I 20 10 X199L4 X10018

RED/YEL

RED/VEL I 5

SEATBACK

BACK

GRN

mm I

BLKIVi2 ' BLU/GR V~ VIOIG ZV

BLK

BLU

DRIVER'SSEATBACK RECLINERMOTOR

VIO

DRIVER'S SEAT CONTROLSWITCH

ON LUP -- J

FRONT

12 GRNIVIO f 1

HEIGHT

POSITION

I BACKLFRONT

CUSHIONTILT

m m

GRNIYEL /

BLKIYEL I VIO/RED / BLU/REOT 1 .'k- - 2 ';' `_ 2

GRN

DRIVER'S SEAT HEIGHTMOTOR

BLK

DRIVER'S SEAT MOVEMENTMOTOR

VI.

BLU

BAN

BR N "

1994-98 Except 318ti

DRIVER'SSEAT CUSHION TILT MOTOR

RED/VEL PASSENGER'SSEAT CONTROL SWITCH

5 SEATBACK

BACK

FRONT

HEIGHT

m n BACK

BLK/VIOT GRN/VIOT BLUIGRY~ VIOIGRYi L L 1 1 1 _2 lll. 1 _ _2 lll. BLK

GRN

BLU

M VIG

PASSENGER'S SEATBACK PASSENGER'S SEAT RECLINERMOTOR HEIGHTMOTOR

835¢7

GRNIYEL I

POSITION

FRONT

m m1

BLKIYELi VIO/REDiBLUIREDt

1 GRN

CUSHIONTILT

PASSENGER'S SEAT MOVEMENTMOTOR

_ _2

VIO

MBLU

BAN I

BRG203 PASSENGER'SSEAT CUSHION TILT MOTOR

ELE-244 ELECTRICAL WIRING DIAGRAMS Power

HO_TA_TALL_TIM_ES_

I I

H_O_TA_TALL_TIMES_

FUSE FB 10

FUSE F40 30=

X1_0015

RED/YEL 5 SEATBACK

FRONT

y 12 RN/V'O'

GRIN

CO DRIVER'S SEAT NTROLSWITCH

HEIGHT

POSITION

BACK y . . . _ . .y

...

..y -» .

BLK/V I2 BLU/GRV' ^`O/G 'of BLK

BLU

DRIVER'SSEATBACK RECLINERMOTOR

ZVI

VIO

FRONT POWER IDISTRISUTIONBOX

TX10018 I

RED/YEL

BACK

Seats

FRONT

11,

GRN/VEL'

GRN

DRIVER'SSEAT HEIGHTMOTOR

CUSHIONTILT

BLK/YEL,

ELK

VIO/R 2.L .LLU/REO '

ORIVER'SSEAT MOVEMENTMOTOR

VI .

BLU

BRN

SPIN .'

DRIVER'SSEAT CUSHIONTILT MOTOR

RED/YEL PASSENGER'SSEAT CONTROLSWITCH

5 SEATBACK

HEIGHT

BACKIFRONT

BACK

BLK/VIOT GRNIVIOTBLU/GRVT VIOIGRVT 2

CUSHIONTIL

FRONT

GRN/VELT BLK/YELT VIO/R EDT BLU/REDT

-T-T _ _1

1SGRN

BLU

_ _2

VIOT

PASSENGER'S SEATBACKPASSENGER'SSEAT RECLINERMOTOR HEIGHTMOTOR

83942

POSITION

GRN

_ _2

ELKT

PASSENGER'SSEAT MOVEMENTMOTOR

BRN

BRN VIOBLUi

PASSENGER'SSEAT CUSHION TILT MOTOR

G201

ELECTRICAL WIRING DIAGRAMS

ELE-245

Heated Seats

1992-98 Except 318ti HOT IN RUN.1 ~AND START

HOT AT ALL TIMES

rIF ----------------------------------L~_____________________________________-i----J - SE 123 SA

S I x19o~

GENIBLU

PUSS FE 16A

-1FRONTPOWER IDISTRIBUTION BOX

x>-D

RED/-

INTERIOR LIGHTS SYSTEM

PASSENGER'S BEATHEATER SWITCH

G203J-G310 (2DOOR) (4 DOOR)

83550

ELE-246

ELECTRICAL WIRING DIAGRAMS

Heated Seats 1995-97 318ti

HOTIN RUN TANDSTART

HOTAT ALL TIMES -------------------------_--------FUSE 14 5-_____________________________________ aI"'D"1. B

rTFUSE ' F23

GRNIBLU

fifi

63939

RED/VIO I

-----_-_-__--------------------

,FRONTPOWER 1DISTRIBUTION BOX

UNLOADER RELAY . TERMINAL15

ELECTRICAL WIRING DIAGRAMS

Lumbar Control 1998

HOTATALLTIMES __ POWER FUSE ---1 FRONT DISTRIBUTION BOX F40 30A - 20TX 10018 RED/YEL R E D/YE

3Ll DRIVER'S SEAT LUMBAR SWITCH

4 WHT/RED 2^ NCA

2 WHT/BLU 4^ NCA

M NCA 1 ..

NCA 3 ...

BRN I

BRN

DRIVER'S SEAT LUMBAR SUPPORT MOTOR/ VALVE

ELE-247

ELE-248

ELECTRICAL WIRING DIAGRAMS

Power Sunroof HOTATALLTIMES ~FRONT POWER DISTRIBUTION BOX RED COMFORT RELAY

2y' RED/VIO'

9y'

8 SPIN

FRDINT POWER FUSE I DISTRIBUTION BOX F1 30A J

VIO/YEL I " F-1992 VIO/YEL~ 9 _X_ 13012

" BRNI

POWERWINDOWS SYSTEM

SUNROOF SWITCH

ICOMFORTI RELAY CONTROL

CENTRALLOCKING MODULE

G202

SUNROOF MOTOR

SUNROOF CONTROL ASSEMBLY

1992-93

STEP- BYSTEP SWITCH

MICROSWITCH

BRNT BRNI

G203

1 69042

HOTATALLTIMES ~ 1FRONTPOWER DISTRIBUTION BOX RED

RED

________---_

2y /

4 BLK/G RN

RED/BLU1 " RED/B1-U 1

COMFORT RELAY

__-_-____

RED/BLU 5

79 FRONT POWER ~ DISTRIBUTION BOX

Fi/9 E 5A -I

! _I

BODY ELECTRONICS CONTRO MODULE (ZKE IV)

SUNROOF SWITCH

Y I M

SUNROOF MOTOR

STEP-BYSTEP SWITCH

NCA BRNI BRNI 1 G203 83567

MICROSWITCH

SUNROOF CONTROL ASSEMBLY

1994

ELECTRICAL WIRING DIAGRAMS

ELE-249

Power Sunroof

HOTIN ACCY, RUN ANDSTART FRONTPOWER fi J j FUSEI DISTRIBUTION BOX V 30A I 2 RED/VIO

NCA SUNROOF SWITCH

I --

SUNROOF MOTOR

SUNROOF CONTROL ASSEMBLY

1995 Except 318ti

MICROSWITCH

STEP-BYSTEP SWITCH

NCA 2y .1911 BRNI AL G203 84194

HOTATALLTIMES

FUSE1FRONT POWER DISTRIBUTION BOX Fl soA

L 2

GRY/RED 6

RED/VIO

INTERIOR LIGHTS SYSTEM

OPEN

1 X272

BRNNI

3 4 BLK/YES WHT/YELl

X13176 SUNROOFCONTROL ASSEMBLY

2X272

1996-97 Except 318ti

X13176

BLK/REDI BLK/GRN

BRN

SUNROOF SWITCH CLOSE

10 BODY ELECTRONICS ~CONTROLMODULE i (ZKE IV)

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-250

ELECTRICAL WIRING DIAGRAMS

Power Sunroof 1998 Except 318ti

HOTATALLTIMES

FUSE, FRONT POWER DISTRIBUTION BOX F1 L~30A J -

RED/V10

GRY/RED 3

INTERIOR LIGHTS SYSTEM SUNROOF SWITCH

OPEN i CLOSE

X272

4 BRN 6

2 BLK/YEL 5

X272

BRN

104866

1 WHT/YEL 4

BLK/RED

BLK/G RN

BRN ~- G203

.7 OFF

X13176 SUNROOFCONTROL ASSEMBLY

X 3176

BODYELECTRONICS I CONTROLMODULE i (ZKE IV)

ELECTRICAL WIRING DIAGRAMS

ELE-251

Power Sunroof HOT AT ALL TIMES FRONT POWER DISTRIBUTIONBOX - .I RED

RED

-- - - -- - -- -

- - -- - --2 REDIBLU~

COMFORT RELAY

REDIBLU

I _

19I X13254

FRONTPOWER FUSE I DISTRIBUTION BOX I 30 .4 J -

I I

-I I

BODY ELECTRONICS CONTROL MODULE

REDIVIDI NCA

SUNROOF CONTROL ASSEMBLY

1995 Early Production 3 18ti

NCAI 2 .L BRNI BRNI 1 G203 84238

HOTATALLTIMES

RED/VI 1

SUNROOF CONTROL ASSEMBLY

6 BLKIYELI WHT/YELI

BRNI

BLK/GRNI

BLKIRED

INTERIOR LIGHTS SYSTEM

BRN

I t G203

GRY/RED

SUNROOF SWITCH

rI I I

84240

BRN1

18j, X132 54. BOGY 1 ELECTRONICS I CONTROL --- MODULE

1995 Late Production & 1996-98 318ti Sliding Sunroof

ELE-252

ELECTRICAL

WIRING

DIAGRAMS

Power Sunroof HOTATALLTIMES FflONT POWER DISTRIBUTION BOX

BLK/GRN RED/BL

I .

FUSEIFRONTPOWER DISTRIBUTION BOX F1 Z30A

19 - -I BODY ELECTRONICS ICONTROL - MODULE

RED/V1110' NCA SUNROOF SWITCH

~E~7

1 1

STEP -BY SWITCH

1 ---

SUNROOF MOTOR

SUNROOF CONTROL ASSEMBLY

1997 318ti Folding Sunroof

MICROSWITCH

NCA BRNI BRNI 1 G203 88588

HOTATALLT_IMES FPONTPOWER - i DISTRIBUTIONBOX

RED

r I

FUSE F1 ,30A

I J

FRONTPOWER DISTRIBUTIONSOX

REDIV IO 1

8 SL

GRN

FOLDING SUNROOF COMFORTRELAY

BLKIGRN

BLK/RED

BLK/YEL

SRN

GRY/RED

BLK

GRN

1 2J.

BLK/GRN

BLKIRED

191

181 X7325

I I

I FOLDING SUNROOF MOTOR

104876

BODY ELECTRONICS CONTROL MODULE

TIP OPEN

FOLDING SUNROOF SWITCH

4 BRN 1

1998 318ti Folding Sunroof

ELECTRICAL WIRING DIAGRAMS

ELE-253

Convertible Top 1994-97 HOTACCV, RU,,NANDSTART US

HOTATA,~LLTIMES

FUS r/FUSE--___-

, 3

CTRL BIG CTRLSIG END

12V

PO STN SIG PO STN SIG END

SPIN

G205

BLK/RED

BLU/GRN

GRYIBLK

RED/GRNIYEL

YEL/BLU

2 3

BLK/BLU

VEL/BRN

BLU/VEL

CTRLSIG

VEL/GRN

x1 1

TOP OPEN BIG

BLKIBLU

VIO/WHT

,7 l B

GRNIBLK

WHT/GRN

11 12

GRN/GRY

ILK

BLKIGRN

DATASIG ROLL-OV ER SIG DATASIG GND PWRSUPPLY

5 B

BRN/OR G

BLKI VIO

BLKIGRN

BLK/GRN

20 21 22

WHT/VEL

WHT/BLU

GRN1VI0

BRNIORG

-I

GRV/RED -

CONVERTIBLE TOP ACTUATING SWITCH

INTERIOR LIGHTS SYSTEM

WHT/BLU

~ 2B X]1]`z4 9 WHT/BLK

CLOSE OFF N-H

BRN/ORG

BRN/ORG- fI

BLK/BLU

671-E L

BLK/

11~V/HT/G R N

BRNIORRG

BODY ELECTRONICS CONTROL MODULE (ZKEIV)

LEFT ROLLOVER PROTECTION ACTUATOR

5 7

BRNIORG

BLK/BRN

' X11399 CONVERTIBLETOPDONTRGLMODULE

RIGHT ROLLOVER PROTECTION ACTUATOR

BLKIWHT

WHT/VEL

WHTIVIO BRN/WHT

TRUNKLIOSIG

WHT/VIO

BLK/VIO

DATASIG

BLKIBLU

BLK/BLU

DATASIG

BLK/WHT GRN/GRV

BLKIGRN

TOP CLOSED BIG

ROLLOVERSENSOR

WHT/VIO

DATASIG SPOSIG

GRN/VIO

BLK/BRN

DATA SIG

VIO/GRN

157

GND

REAR WDO BLWPSIG

BRN

B LK/GRN

POSTNSIG

PWRSUPPLY

X1315fi

tSUPPLY

DATA SIG

HOTACCV,R'U~NANDSTART HOT AT ALL TIMES -_____-/FPOWER DINT IDRSRBUTIONBOX 42E------~F27E

GRV/RED

5 B 7

CTRLSIG

-------

FU FUSE

BLKIYEL SLUIRED

CT RLSIG

/FUS E

HOTAT 777AIIBL~~LTIMES

CONVERTIBLETOP POSITION MICRO SWITCH

CONVERTIBLE TOP ENDPOSITION MICRO SW ITCH

BLK/BLU SPIN

w I_ HARD OFCONNECTOR1 (IN CONVERTIBLE TOP

BRN/ORG

am BLKIRED BRN /ORG

G~ RN/BLK REAR WINDOW BLOWER MICRO SWITCH

RED ~~

WHT/BLK ~~ DEFOGGER SYSTEM

BRNI

BRN

CRY

LOCKED

UNLOCKED

WHTIBLU ~~ BLU

j G202 03584

BLU

./EEL ELK-

BR B~

CONVERTIBLE TOP STORAGE MOTOR

CONVERTIBLE TOPMOTOR

WINDSCREENCOWLPANEL LOCK MICROSwITCH (1996-97)

ELE-254

ELECTRICAL WIRING DIAGRAMS

Convertible Top 1998

HOTAT HOTINRUN, ALLTIMES ACCYANGSTART _ _ 7II ~~ _ _ AUXILIARY FUSE F FUS E , r 77̀ F_US_E BOXI =35 I IL , F43S L 20-J . _

2 281 1 RED

HOTAT ALLTIMES

Xt00 ]E

,41x19010

' WH1I

20Y

GRYIRED

GND

LOCK CTRLSIG

1 7

BLK/RED N

~~ G904

RED ,D " ~nlzo1

GRN/ J ELK

VIOL j GRN

141X70012 GRNI VIO GRN/VIO

WHTlBLU

BLKK/WHT

I I

POSITION SIG

S 8

YEL/BRN BLK/GRN

8LK/BLU

BRNIORG WHT/BLU

BLK/VIO

WHTIVIO

BLK/GRN

21 ROLLOVER SENSOR

RIGHT ROLLO ER

II q OUATOR N BLKIVIO

WHT/VIO

BLK/BLU

BLK/BLU VIO/WHT

J 7 18

GRNI .LK

J 9 1_10

DATA SIG

WHT/GRN

SPEEDSIG TOPCLOSESIG

113 14

LEFT ROLLOVER PROTECTION ACTUATOR

BLK/WHT

11 J

B 8

GRN/BLK

8LK/BRN

GND

REARBLOWER

SS OUTPUT

157

DATASIG

ROLLOVER PROTECTION WARNING IN D

BLKIGRN

YEL/GRN

J 2 Ir J3

PWRSUPPLY

INSTRUMENTCLUSTER VIO/GRN 2 BLK/WHT 4

I I 1

BLU/YEL

3 4

TOPOPENSIG

GRNI

BLK/BLU

POSITION SIG GND CTRLSIG l 1i

241x190]7

GBNKI

YEL/BLU

. . .ITIONSIG

FUSE~FRONT POWER 1DISTRIBUTIONBOX P27 5A _j

BLU/GRN GRYLK

J 3 9

isUPPLY

HOTAT ALLTIMES

.)/RED 8-t

4 5

12V

HOTINRUN, ACCYANDSTART

HT/ EL

CTRLSIG CTRLSIG CTRL

CTRLSIG

GqN [

,BT

,2 ;

LOCKCTRL

BIx1oo17

GRN/ I DATA LINK CONNECTOR

W~T

HOTINRUN ANOSTART

FUSE FUSE FUSE F7 F24 F42 S .-0-7-0-

BLK/WHT BLK/GRN

CONVERTIBLETOP CONTROL MODULE

I I I I

I 18 W HT/RED 1 X1 3254 I 1 5 WHT/YEL 17 11

RED/GRN

WHTIGRN

BRN

__I X13255

BODYELECTRONICS CONTROL MODULE (ZKE IV) I

NCA I NCA

C-/BL BL U , BRN

I __I HARDTOP CONNECTOR 1

NN=A (

BRN/YEL

NCA NCA BRN REAR WINDOW BLOWER MICRO SWITCH

104867

CONVERTIBLETOP STORAGE LID LOCK MOTOR

rrr r

DEFOGGER SYSTEM

BLK

AL G312

UNLOCK

LOCK

WINOSCREENCOWLPANEL LOCKMICROSWITCH

CONVERTIBLE TOPMOTOR

CONVERTIBLE TOP-END POSITION MICROSWITCH

TRUNKLID MICROSWITCH

I 1 I

ELECTRICAL WIRING DIAGRAMS

ELE-255

Radio/Cassette/CD/Speakers

HOTAT ALLTIMES

1 2 3 4 5 6 7 8 9 10 11 12

HOT INACCY, RUNANDSTART

1993

YEL/RED BLU/RED YEL/VIO WHT/BRN VIO/WHT BLU/VIO

f3 14 15 6

YEL/BRN RED/WHT BLK/WHT BLUIBRN YEL/GRY GRY/RED BLU/GRY BRN WHT

1992

LEFT FRONT HIGH RANGE SPEAKE INTERIOR LIGHTS SYSTEM

YEL/VIO 4 YELIGRY I .,

G202

RADIO

6LU/RED

8LU/BRN

ANTENNA AMPLIFIER AM/FM

VSSI1 2 PUTPUTI

BLU/RED 2

BLK/WHT ~

1 -- 1, 10

BLK

WHT/BRN

BLU/VIO 4

BLU/GRY I,

TELEPHONE TRANSCEIVER 87730

HOT INACCY,RUNANDSTART

RIGHT FRONT LOW RANGE SPEAKEF

RIGHT

I I REAR S EAKEF

HOT AT ALLTIMES FUS, FRONTPOWER I DISTRIBUTION BOX F9 20A

FUSE F44 15A (OTHERS) 20A (1997) Ll------

' I I

LEFT REAR SPEAKEF

RIGHT FRONT HIGH RANGE SPEAKEF

BLU/BRN I

INSTRUMENT CLUSTER

1992-93 6 Speaker System

J-J__J

CD CHANGER (1997) I 2 3 4 5 6 7 8

YEL/RED BLU/RED (1994-1996) YEL/VIO WHT/BRN VIO/WHT BLU/VIO YEL (1997 YEL/BRN RED/WHT 9 BLK/WHT 10 11BLU/BRN YEL/GRY 12 GRY/RED 13 BLU/GRY 14 f5 16

BAN WHT

BLKIWHT

BLU/BLK (7997)

LEFT FRONT HIGH RANGE SPEAKER _

BRN

VSSI pUTPuT

WHT/ 6 BRN X40

RIGHT FR NT ` 1 y I ILO BLU/BRN RANGE SPEAKER

BLU/RED

10 B~ WHT/ BE R-N 1

TELEPHONE CONNECTOR

-li

BLU/BLK (1994-1996) I BLU/BLK (1997) "

1994 I TO I TELEPHONETRANSCEIVERI 1996

86095

INSTRUMENTCLUSTER I-

LEFT REAR SPEAKER

{ 6202

RADIO

LEFT FRONT LOW RANGE SPEAKER

1997

BLU/BRN

I I

I (

I ANTENNA AMPLIFIER

BLUIVIO BLU/GRY

RIGHT FRONT HIGH RANGE SPEAKER

RIGHT REAR SPEAKER

1 99497 Except 318ti 10 Speaker System

ELE-256

ELECTRICAL WIRING DIAGRAMS

Radio/Cassette/CD/Speakers 1998 Except 318ti 6 Speaker System HOT INACCY,RUNANDSTART

HOTATALLTIMES

I T ------7F-----j FRONTPOWER FUSE F44 15A

FUSE . F9 20A

28Y

18Y

VIO/ WHT

I DISTRIBUTION BOX

I -I

RED/ WHT

CDCHANGER

YEL/RED

BLU/BLK

WHT/BRN

3 5

6 7 8 9

10 11

14 15 16

YEL/VIO

VIO/WHT BLU/VIO

YEL/BRN ,

" -YEL/

YEL/BRN

RED/WHT

BLU/BRN

BRN

WHT

" - _ BRN,

~I G202

YEL/GRY

VSS (OUTPUT(} -- - ---"

RIGHT FRONT LOW

BLU/BLK --( BLU/BRN {

lSPEA ER

BLK/WHT

BLU/BLK

INSTRUMENT CLUSTER

BLU/BRN WHT/BRN TELEPHONE 6 CONNECTOR X400

BLU/VIO

F 2

108825

LEFT REAR SPEAKER

YEL/VIO

RADIO

I 2

I SPEAKER

INTERIOR LIGHTS SYSTEM

YEL/GRY GRY/RED BLU/GRY

LEFT FRONT HIGH

YEL/RED

YEL

BLK/WHT

LEFT FRONT LOW RANGE SPEAKER

YEL/RED

BLU/GRY

~ .I ANTENNA AMPLIFIER

RIGHT FRONT HIGH RANGE SPEAKER RIGHT REAR SPEAKER

ELECTRICAL WIRING DIAGRAMS

ELE-257

Radio/Cassette/CD/Speakers fi: ;...._..,

1998 Except 318ti 10 Speaker w/CD Changer System

r. . . L

rM~N "IIIINN

1998 Except convertible 10 Speaker w/CD Changer and Top HiFi System

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

ELE-258

ELECTRICAL WIRING DIAGRAMS

Radio/Cassette/CD/Speakers

1998 Convertible 10 Speaker w/CD & Top HIF! System HOT IN AC CY, RUNANDSTART

FRONT POWER RIBUTIONBOX I

FUSE ? F44 15A

ROTAT HOTAT HOTINACCY, ALLTIMES ALLTIMES RUN AND START ----------FUSE E33 t IDA

FUSE F9 t 20A

SPATIAL S

FUSE F43 } SA

Viol WH T

WR7I

GRYIRED

VEL/RED

BLU/RED

YELIBLK

WHT/BRN

VIO/WHT

BLU/BLK

7 e

VEL

SRN

BRN/ORG RED/WHT

BLU

BLK/WHT

BRN/ORG

BEN

BRN/ORG

GRY/RED BRN/ORG WHT

11111

X18120 YEL

BLU

BRN

GRY

5 6

BLK

GRN VI .

INCA

RED

WHT

SPIN/ YEL

G312 1~

CONTROLIMODUOLE GRNIB K

BEN

(--_

III G202

RED/WHT

WHT BR N

2 3

0RN

BLU/WHT

BLU/BRN

BLU/RED 9 BLU/BRN 10 BLU

11 12

BEN

XB05 SENIOR .

BLU/BLK

NEM

Ills _ _""" _ -

OMENIENINE

X18520

RADIO

2 SPIN

SUBWOOFER

BRN

YIELI

VEL

15 16

I I

~BEARWINOOW ~ BLOWER MICRO SWITCH l l

I I

INTERIOR LIGHTS SYSTEM

LAV

18 1

GRN

SPIN BLK

WHT 5

NCA

B 7

RED GRY

VIO

YEL

BLU

\ NN~~4 2 (

NC!-<

RED/WHT "

BRN

BLU/BLK

BL U/BRN YEL/W H7

24 25

YEL BRN

21 ,

VEL/ BRN

VEL/BRN

(18520

q ! 3

YE L/RED

JI,G312

COCHANGER

X 806

VIO/VEL

1 %102X 8 IFIAMPLIFIER WHT

~IHI

ANTENNA AMPLIFIER

" = BL /yy11T=~I V55

OUTP UT

INSTRUMENTCLUSTER . .R HT/

LEFTFRONT MIDRANGE SPEAKER

108830

LEFTFRONT HIGH RANGE SPEAKER

LEFT MID-HIGH RANGE SPEAKER

LEFTFRONT LOW RANGE SPEAKER

LEFTREAR HIGH RANGE SPEAKER

LEFTREAR LOWRAN0E SPEAKER

LEFTREARSPEAKER

RIGHTFRONT MIDRANGE SPEAKER

RIGHTERONT HIGHRANGE SPEAKER

RIGHT MID HIGH RANGE SPEAKER

~~~ RIGHTFRONT LOW RANGE SPEAKER

RIG HT REAR LOW RANGE SPEAKER

6 TELEPHONE

RIG HT REAR HIGH RANGE SPEAKER

RIGHT REAR SPEAKER

ELECTRICAL WIRING DIAGRAMS

ELE-259

Radio/Cassette/CD/Speakers HOTINACCY.RUNANDSTART r 1FFUSE F44 15A

HOTATALLTIMES FUSEII FRONTPOWER DISTRIBUTION BOX F9 20A 1

Lam__----

2.1 VIG/ WHT

-_I

CD CHANGER (1997) I YELIRED 2 BLU/RED 1995-1996 BLU/BLK 1997 3 YEL/VIO 4 WHTIBRN 5 VIO/WHT 6 BLUIVIO 7 YEL 1997 e YEL/BRN 8 RED/WHT 10 BLK/WHT INTERIOR LIGHTS SYSTEM 11 BLU/BRN 12 YEL/GRY 13 GRY/RED 14 BLU/GRY BRN " BRN 15 16 WHT G202 RADIO

LEFT FRONT LO W RANGE SPEAKER LEFT FRONT HIGH RANGE SPEAKER

YEY~"LEFT YEL/GRY ,L

II SPEAKER

I BLU/BLK

(1995-1996) BLU/8LK (7997)

RIGHT FRONT LOW RANGE SPEAKER

IpUTPUTI~~ VSSI 2 BLK/WHT INSTRUMENT CLUSTER

TELEPHONE CONNECTOR

11995-97 ~1 8t' 16 Speaker I System

RIGHT FRONT HIGH RANGE SPEAKER BLUNIG

WHT/

X13F

I -~

RIGHT REAR SPEAKER

BLU/GRY

ANTENNA AMPLIFIER

89253

FUHO7INACCY, NANDSTART

HOTA7 ALLTIMES

FUSE F9 20A

IDIS7RIBUTIONBOX I 1

vlol WHT -Y3, 1 YE

__J

! CDCNAMOER

YEL/RED LU/BLK EL/VIO 4 WHT/BRN 5 VIO/WHT 7 LU/VIO YEL 8 .RN EL/ 9 ED/WHT LK/WHT 11 BLUIBRN 12 EL/GRY G RY/RED 13 14 BLUIORY 15

LEFT FRONT LOW RANGE SPEAKER LEFT FRDN7 RANGE SPEAKER

LEFT 11A SPEAKER ' *-

G202

RIGHT FRONT Low RANGE SPEAKER

RADIO

VSS Ir2 - B-K-W-7~ 1=UUTPU-I

RIGHT FRONT HIGH RANGE SPEAKER

INSTRUMENT CLUSTER

TELEPHONE CONNECTOR

6 X1

WHT/ BRN

m I

AMPLIFER I 1-891

(

.Y . .LL/

RIGHT SPEAKER

1998 1318ti 6 Speaker I System ,

ELE-260

ELECTRICAL WIRING DIAGRAMS

Radio/Cassette/CD/Speakers

1998 318ti 10 Speaker w/CD Changer System HOTINACCY . HOTAT HOTAT RUNANDSTART ALLTIMES ALLTIMES ----------------- FRONTPOWER I DISTRIBUTION ONBOX FUSE FUSE FUSE144 133 F9 I 15A 10A 20A I

REDIWH~2

5 (

-----

fi / 7( BLU/ 9~ 10~

YELISLK 11 X 12

INTERIOR LIGHTS SYSTEM

GRYIRED

SUBWOOFER _RED/WH~

YEL/RED

BLU/RED

YEL/BLK

WHT/BRN

5 fi 7 8 9

BRN/ORG

BRN

BLU/VIO

VIO/WHT

BLU/GRY

BLU/BLK

BLU/WHT

YEL

BLUIBRN BLUPPED

8 9

RED/BLK/WHT

BRNIORG

BRN/ORG

GRYIRED

BRNIORG

BRN

WHT

X78720

I T T

BLU/BRN

YELIGRY

BLU/BLK

YEL/BLK BRN/ORG

3 4

BLU/RED

5 ~

YEL

BILL)

BRN

GRY

BLUIBRN

5 B

ELK GRN

YEL BRN

10 11

VIO

BLU

NCA

BRN

RED

BF .I .FG BLU/RED

1 ,1 15

YEL/RED

BRNIORG

10 RADIO

BLUIBRN YELIG

7 B

WHT

X1fi520

18 19 20 YEL/RED

YEL/BRN

BLU/BLK BLU/BRN

23 24

YEL/BLK

YEL/BRN

26 XBDB

WHT

HIFI AMPLIFIER

ANTENNA AMPLIFIER "

ILK/1"TI VIS I I OUTPUT INSTRUMENTOLUSTER

CDCHANGER

BL.

B{ TELEPHONE CONNECTOR

X79305

1,18890

LEFTREARSPEAKER

RIGHT MID- HIGH RANGE SPEAKER

RIGHTFRONT LOW RANGE SPEAKER

RIGHT REAR SPEAKER

ELECTRICAL WIRING DIAGRAMS

ELE-261

Radio/Cassette/CD/Speakers 1992 10 Speaker System

H OT INACCY,RUNANDSTART

HOT AT ALL TIMES

FUSE F44

FUSE F9

FRONTPOWER

I DISTRIBUTION BOX

TERMINALR

YELIRED

BLU/RED

YELIBLK

WHT IBRN

V IO/WHT

BLU/BRN

BLU/BLK

BLU/WHT

BRN/ORG

YELIGRY

B 9

BLU/GRN

BLK/WHT

BRNIORD

12 1 13

SWORD GRY/RED

BRN/ORG

BRN

WHT

YEL

EL.

BRN

GRY

ELK

GRN

VIO

NCA

9 10

RED WHT

RADIO

YEL/GRN 6202

,fir

RED/WHT

88N

INTERIOR LIGHTSSYSTEM

."_ """"".. ".-"."

RED/WHT 2 . BR=

WHT

BLUIGRY

BLU/VIO

BLU/REO 12 X645

MEMNONME "".""

IIL!!!!r

MMIMEMEMEME EMOMMEMMEM

YELIRED

YEL/BRN

BLU/8LK

BRNIORG

BRN/ORG BLU/RED

5 6

YEL/WHT

YELIBLK

YEL/RED

BRNIORG

BRN/ORG YELIBLK

11 12

X506 HIFIAMPLIFIER

X18529

1 GRN WHT 2 BRN 3

BLK

WHT

NCA

PED

GRV

B 9

VIG YEL

BLU

WHT

WHT/BRN

I I

BLK 10 ,'

BRN

CDCHANGER

BBRNN

BLKIWHT 2 i IVSS ~lo UTPUT INSTRUMENT CLUSTER

'IJI G202

YELIBRN

LEFTFRONT HIGH RANGE SPEAKER

LEFT MID-HIGH RANGE SPEAKER 877152

____j 1

TELEPHONE TRANSCEIVER

X]8]B0

LEFT FRONT MIDRANGE SPEAKER

ANTENNA AMPLIFIER AM/FM

BLKIWHT 1

--- J

22L~2 OR~

LEFTFR0NT LOW RANGE SPEAKER

LEFTREAR HIGHRANGE SPEAKER

LEFT REAR LOW RANGE SPEAKER

LEFT REAR SPEAKER

RIG HT FRONT

SE P EA K R

H SPEAKER E

RIGHT MID-HIGH RANGE SPEAKER

RIGHTFRONT LOWRANGE SPEAKER

RIG HT REAR RANGE H SPEAK E R

RIG HT REAR L SPEAKERE

RIGHT REAR SPEAKER

ELE-262 ELECTRICAL WIRING DIAGRAMS

Radio/Cassette/CD/Speakers

1993 Early Production 10 Speaker System HOT IN ACCY . RUNANDSTART

HOTAT ALLTIMES

FUSE F44

YELIRED

BLU/RED

YEL/ELK

WHT/BRN

5 6

VIO/BLK BLU/BLK

FUSE F9

I FRONT POWER I DISTRIBUTION BOX

6202

SRN

YELIGRN

./-T RE _ BRN

BLU/BRN

BLU/WHT

YEL/GRY

BLU /GRN

REDIWHT

WHT

BLK/WHT

BLU/GRV

BRN/ORG

BLU/VIO

BRN/ORG

11 12

GRV/RED

BRNIORG

15 16

BRN

BLU/RED INTERIOR LIGHTSSYSTEM

X445

WNT (18126

MENNENION MEMNONION

VEL/BRN

./91K BL

BRN/ORG

BRNIORG

BLU/RED

VELIWHT VEL/BLK

7 8

YEL/RED

BRN/ORG

BRN/DRG

VEL/BLK

12 X804 HIFI AMPLIFIER

I I I

WHT

11111111 !!!!III

WHT

__I

ANTENNA AMPLIFIER AM/FM

WHT/BRN

BLK

i_01 ___1 TELEPHONE TRANSCEIVER

BLK/WHT .

BLK/WHT

I VSS OUT(T(=UT

INSTRUMENT CLUSTER

CDCHANGER

LEFTFRONT MIDRANGE SPEAKER

1 86702

LEFTFRONT HIGH RANG, SPEAKER

LEFT MID-HIGH RANGE SPEAKER

LEFTFFIN ; OW RANGE SPEAKER

LEFTREAR HIGHRANGE SPEAKER

LEFTREAR LOWRANGE SPEAKER

LEFTREARSPEAKER

RIGHTFRONT MIDRANGE SPEAKER

RIGHTFRONT HIGHRANGE SPEAKER

RIGHT MID-HIGH RANGE SPEAKER

RIGHTFRONT LOW RANGE SPEAKER

RIGHT REAR HIGHRANGE SPEAKER

RIGH7REAR LOW RANGE SPEAKER

RIGHT REAR SPEAKER

ELECTRICAL WIRING DIAGRAMS

ELE-263

Radio/Cassette/CD/Speakers

1993 Late Production 10 Speaker System HOTINACCV, RUNANDSTART FU0BE F4 15A

HOTAT ALLTIMES _ - -- - - -

FUSE F9

1 FRONTPOWER DISTRIBUTION BOX

20A L_1 __________ .1___J 26Y

167

ANTENNA REDIWHT N

2 ,

" B RN

3 4

NCA 1

YEL/RED

BLU/RED

VELIBLK

WHT/BRN

.1 ./W VI

BLUILUBLKK

INEE ENIN INEE

VIO/BLK

BLUI iO

BLU/GRV

VEL/RED

VELIBRN BLUIRED

8 , 9 ,

BLULU/R1 VELIBLK

X64b

7 9

RE /WHT BR BF

VEL/RED VEL/BLK

""". "" .

._" _"."

10LK/WHT 12

1 2

VEL/BLK

/ORG

1~fER ~ 13 GR /FRED 14~BRNDRG

BRNIORG

INEEN

BRN/ORG . . WHT 1 VELIBRN

BLU/BLK

X1H~12B

6RNIORG

BFNIORG

YEL

BLUIRED

BLU

VELIWHT

B FN GRV

7 B

15 i6HT

4 B

BLU/WHT BLUIBRN

BLK

GRN

VIO

NCA

RED

WIT

VEL/VIO

VEL/GRV

11 12

BLU/BLK

BL U IGRV

X18529

RA010

18 1B 2D YEL/GRN

22 BLU/GRN BLU/BRN

23 24 25

VEL/BRN

26 X946

WHT

H111 AMPLIFIER

I --

ANTENNA AMPLIFIER AMIF :=N ~,

WHTIBRN

CDCHANGER

LEFT MID-HIGH RANGE SPEAKER

LEFTFRONT LOW RANGE SPEAKER

TELEPHONE _~~

67656

BLK

G202

RIGHTFRONT MIDRANGE SPEAKER LEFTREARSPEAKER

RIGHTFRONT HIGH RANGE SPEAKER

RIGHT MID-HIGH RANGE SPEAKER

I -

BLK/WHT

U RIGHTFRONT LOW RANGE SPEAKER

BL .IWHT

RIGHTREAR HIGH RANGE SPEAKER

VSSSC=1V=

RIGHTREAR LOWRANGE SPEAKER

RIGHT REAR SPEAKER

ELE-264

ELECTRICAL WIRING DIAGRAMS

Radio/Cassette/CD/Speakers

1994-97 Except 318ti 10 Speaker System HOTINACCV,RUNANDSTART

HOTATALLTIMES FUSE F33 10A

T i6A (OTHERS) 20A (1997)

28TTT

HOTATALLTIMES FUSE

6~''

FRONT POWER

I DISTRIBUTION BOX

RED// RED/ VIO//I / WHT/ WHT,

19970NLY

YEL

I --i

WHT ~11

CHANGER

G202

INTERIOR LIGHTS SYSTEM 1

YEL/RED

2 3

BLU/RED

YEL/BLK WHT/BRN

VIO/WHT

BLU/BLK

YEL

BRN/OR6

RE D/WHT

BLK/WHT

11 12

BRN/DRG

B FIN /ORG GRY/RED

BRNIORG

BRN

115

WHT

_REDIWHT

VEL/RE0

(1994-1996)

VEL/BRN

(1994-19967

(1997) (19977

BRN

BLU/VIO

BLU/GRY

BLU/WHT BLU/BRN

7 8

BW/RED

BLU/BRN

VEL/GRY

YELL/BL1212 X605 BRNN/OR BLUU/BLK22

X 16126

YELIBLLIB

BRN/ORG 5 6 7

BLUIWHT BLU/BRN

YELIVIO

YELIGRY BLU/BLK

11 12

.FY ./ BL

BRN/ORG

BLU/RED

VEL/RED

BRN/ORG

17 18 19

VEL/GRN

zD ~ 21

YELIBRN "

22 ,

81-11G BLU/BRN

24 E'

VEL/WHT VEL/BRN

25 26

I X606 - I HIFI AMPLIFIER

WHT

I I

ANTENNA AMPLIFIER " CDCHANGER 1997

BLK/WHT

1-- (OUTPUT

INSTRUMENTCLUSTER BILK 6 TELEPHONE CONNECTOR X 400

BLK

BLK 10

TELEPHONE TRANSCEIVER

LEPTREAR LOWRANBE SPEAKER 86093

LEFT MID-HIGH RANGE SPEAKER

LEFTREAR HIGH RANGE SPEAKER

LEFTREARSPEAKER

RIGHTFRONT MIDRANGE SPEAKER

RIGHTFRONT HIGHRANGE SPEAKER

RIGHTMID-HIGH RANGESPEAKER

RIGHTFRONT LOW RANGE SPEAKER

RIGHTREAR HIGHRANGE SPEAKER

RIGHTREAR LOWRANCE SPEAKER

RIGHT REAR SPEAKER

ELECTRICAL WIRING DIAGRAMS

ELE-265

Radio/Cassette/CD/Speakers 1995-97 318ti 10 Speaker System HOTINACCV,RUNANDSTART ____~

HOT ATALLTIMES

FUSE F41 i5 A

2B VIO/ WHT

HOTATALLTIMES ___IFRONTPOWER I DISTRIBUTION BOX FUSE F9 I 20A I

USE

RED/ WHT

1997 ONLY)

RED/ WHT

YEL

S L

CD I ICHANGER I__I

INTERIOR LIGHTS SYSTEM REVEL/RED

1 2 3

BLU/RED VEL/BLK

(1995EARLYPROD)

WHT/BRN 5

VIO/WHT

BLU/BLK

VEL

BRN/ORG

RED/WHT

BLK/WHTG

IT 12

SENIOR BRN/ORG

GRY/FED

14 15

BRN/ORG SPIN

WHT

(19919 5LATEPROD 98&1997)

BLU/WHT

WHT

BEN

3 4

BLU/VIO ELL,GRY

5 fi

VELIRED

YEL/BRN

BLU)RED

BLUIBRN

YELIGRV

11 X606

iLB128

SENIOR .

BLU/BLK

YEL/BLK

4 ,

BRN/ORG .

YEL 2 3

DIWHT

SPIN GRY

BLU/RED

BLK

GRN

VEL

VIO

(1995-1996)

RED

BEN

WHT

BLU

(1997)

X18520

BRN

BLK

4 5

WHT NCA

RED

GRY

VIO

YEL

BLU

VEL/RED

1111111

8 9

L YEL/VIO

L VEL/GRY

, 11

BLU/BLK

BLU/GRY

BRN/ORG

BLU/RED YEL/ RED

RED/WHT

SPIN

BLU/BLK

YELIRED YELIGRV

VEL/BRN

BLU/GRN

BLUIBRN

YELIBLK VEL/BRN

25 26 X606 HIFIAMPLIFIER

WHT

K1B520 2

16 17 19

(1995 EARLY PROD) 2

BLU/BRN

BRN/0-

(1995LATEPROD 1996 & 1997)GHN

L BLU/WHT

BRN

NCA

RADIO

(1995EARLYPROD)

(1995LATEPROD 1996 & 1997)

BLU

1 -1 1 _1

ANTENNA AMPLIFIER "

SPIN

+ G211 (2000R) G310 (4 DOOR)

BLK/WHT22{IVSB I I OUTPUT

CDCHANGER

INSTRUMENTCLUSTER

BLK 6 X13305

TELEPHONE CONNECTOR

LEFTFRONT LOW RANGE SPEAKER 89260

erennen

erenrten

~~ .~ ., . . ., .. .. . .,.~.,

arennen

erenrten ----

RIGWRANGE SPEAKER

RIGHT REAR HIGH RANGE SPEAKER

RIGHTREAR LOWRANGE SPEAKER

RIGHT REAR SPEAKER

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

INDEX WARNING Your common sense, good judgement, and general alertness are crucial to safe and successful service work . Before attempting any work on your BMW, read the warnings and cautions on page vi¡ and the copyright page at the front of the manual . Review these warnings and cautions each time you prepare to work on your BMW. Please also read any warnings and cautions that accompany the procedures in the manual .

A ABS (anti-lock brakes) See Brakes Accelerator and throttle linkage See Maintenance program Air conditioning general information 640-1 air distribution motor, replacing (rotary knob) 640-10 air distribution motors 640-9 blower motor, removing/installing 640-1 blower motor resistor pack, replacing 640-3 compressor, replacing 640-12 compressor clutch 640-13 condenser, replacing 640-14 control head 640-7 removing/installing (digital -display) 640-8 removing/installing (rotary knob) 640-7 control module removing/installing (digital-display) 640-8 removing/installing (rotary knob) 640-8 evaporator, removinglinstalling 640-17 evaporator temperature sensor, replacing 640-17 expansion valve, removing/installing 640-16 microfilter, replacing 640-18 receiverldrier, replacing 640-15 sensor fan for interior temperature, replacing 640-9 warnings and cautions 640-11 Air distribution (flap) motor See Air conditioning See also Heating Air filter See Maintenance program

Airbag system (SRS) general information 721-1 contact ring, replacing 721-3 driver side airbag, removing/installing 721-5 front crash sensor, replacing 721-4 front side-impact airbag, removing/ installing 721-7 front side-impact airbag crash sensor, removing/installing 721-5 passenger side airbag, removing/ installing 721-6 sensors and electronics 721-1 SRS warning light and fault display 721-2 systems 721-1 ZAE control module, replacing 721-5 Alarm system See Central locking and anti-theft Alternator See Battery, starter, alternator Anti-freeze (Engine coolant) See Maintenance program Anti-theft See Central lockíng and anti-theft AST (Al¡ season traction) 300-4 ATF (Automatic transmission fluid) See Automatic transmission Automatic transmission See alsoTransmission-general general information 240-1 ATF, draining and filling 240-2 ATF leve¡, checking 240-1 transmission removal and ínstallation 240-4 transmission, removinglinstalling 240-4 transmission service 240-1 Auxiliary fan See Cooling system Axle joint See Maintenance program

B Back-up light switch See Manual transmission Ball joint See Front suspension Battery See Battery, starter, alternator Battery, starter, alternator See also Maintenance program general information 121-1 alternator, removing/installing (4cylinder engine) 121-5 alternator, removinglinstalling (6cylinder engine) 121-6 alternator brushes, inspecting/ replacing 121-7 alternator service 121-4 batterycharging 121-4 battery load voltage test 121-4 battery open-circuit voltage test 121-4 battery service 121-3

Battery, starter, alternator (cont .) battery testing 121-3 charging system quick check 121-2 charging system troubleshooting 1212 hydrometer testing 121-3 solenoid switch, removinglinstalling 121-10 starter service 121-7 starter troubleshooting 121-7 starter, removing/installing (4-cylinder engine) 121-8 starter, removing/installing (6-cylinder engine with automatic transmission) 121-9 starter, removing/installing (6-cylinder engine with manual transmission) 121-8 static current draw, checking 121-2 voltage regulator, removing/installing 121-6 Bearing, wheel See Front suspension or Rear suspension Blower motor See Air conditioning See also Heatíng BMW emblem See Exterior trim, bumpers Body-general general information 400-1 body assembly 400-1 central body electronics 400-4 convertible models 400-2 coupe models 400-2 electronic immobilizatíon system 4004 exterior and aerodynamics 400-2 heating afhd air conditioning 400-5 instruments and controls 400-4 interior equipment 400-3 seats and seatbelts 400-3 Body side molding See Exterior trim, bumpers Brake fluid See Maintenance program Brakes general information 340-1 antilock brake system (ABS) 340-11 inspection 340-12 wheel speed sensors, replacing 340-12 bleeding brakes 340-3 brake booster, removinglinstalling 340-8 brake caliper, removing/installing 340-6 brake pads, calipers, and rotors 340-3 brake pads, replacing 340-4 brake rotor, removing/installing 340-7 master cylinder, removing/installing 340-7 parking brake 340-10 adjusting 340-10 . cable, replacing 340-11 shoes, removinglinstalling 340-11

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

INDEX Brakes (cont.) pressure bleeding brakes (except cars wíth AST) 340-3 troubleshooting 340-1 Brushes, alternator See Battery, starter, alternator Bulbs See Exterior lighting See also Instruments Bumpers See Exterior trim, bumpers

C Camber See Steering and wheel alignment Camshaft See Cylinder head and valvetrain Camshaft position sensor See Ignition system Camshaft timing chain general information 117-1 camshaft timing chain, 4-cylinder 1172 camshaft timing chains, 6-cylinder 117-6 camshaft timing chain, removing (4-cylinder engines) 117-2 camshaft timing chains, removing (6-cylinder engines) 117-7 vanos (variable valve timing) 117-14 control unit, removing 117-16 system operation, testing 117-14 Caster See Steering and wheel alignment Catalytic convertor See Exhaust system Cautions viü Center bearing See Driveshaft Center console See interior trim Central body electronics (ZKE IV) 515-8 Central locking system (ZVM) 515-7 Central locking and anti-theft general information 515-1 door handles and Iocks 515-1 door striker, replacing 515-6 front door handle, removing/ installing 515-3 front door lock, removing/installing 515-1 rear door handle, removing/installing 515-5 rear door lock, removing/installing 515-4 EWS II control module, replacing 51510 EWS II ring antenna, replacing 515-10 EWS II transmitter/receiver module, replacing 515-11 locking system and electronic immobilization 515-7 luggage compartment locking actuator, removing/installing 515-6

Clutch general information210-1 clutch hydraulic system, bleeding and flushing 210-2 clutch, inspecting and installing 210-5 clutch master cylinder, replacing 210-2 clutch, removing 210-4 clutch slave cylinder, replacing 210-3 transmission pilot bearing, replacing 210-6 Clutch fluid See Maintenance program Coil See Ignition system Coil spring See Rear suspension Component locations See Electrical component locations Compressor See Air conditioning Compressor clutch See Air conditioning Condenser See Air conditioning Control arms See Front suspension See also Rear suspension Convertible top general information 541-1 manual convertible top 541-1 lid release mechanism 541-2 replacing 541-2 visor latch 541-1 visor latch píate 541-1 power convertible top 541-2 drive motor, replacing 541-7 emergency operation 541-7 front latching mechanism 541-4 lid 541-9 replacing 541-5 visor latch 541-4 visor latch motor 541-5 visor latch plate 541-4 rollover protection system 541-9 Coolant (Anti-freeze) See Maintenance program Coolant pump See Cooling system Cooling system general information 170-1 cooling fan, replacing 170-8 coolant pump, replacing 170-10 coolant pump and thermostat 170-1 coolant, draining/filling 170-5 cooling fans 170-2 cooling fan, testing 170-4 cooling system service 170-5 cooling system, bleeding (radiator with integral expansion tank) 170-6 cooling system pressure test 170-3 electric cooling fan, replacing 170-8 radiator, removing/installing 170-11

Cooling system (cont .) radiator and expansion tank 170-1 radiator service 170-11 temperature gauge quick check 170-3 thermostat quick check 170-3 thermostat, replacing 170-9 troubleshooting 170-2 warnings and cautions 170-2 Crankshaft position/rpm sensor See Ignition system Crash sensor See Airbag system (SRS) CV joint See Maintenance program See also Rear suspension Cylinder head and valvetrain general information 116-1 camshaft 116-7 camshafts, removing/installing (M42 engine) 116-1 camshafts, removing/installing (M44 engine) 116-3 camshafts, removing/installing (6-cylinder engine) 116-4 cylinder head, disassembly/assembly 116-1 cylinder head and valvetrain, reconditioning 116-7 cylinder head 116-7 hydraulic cam followers, checking and replacing (M42 and al] 6-cylinder engines) 116-9 hydraulic valve adjusters, checking and replacing (M44 Engine) 116-8 valve guides 116-10 valve seats 116-12 valve springs 116-12 valve stem oil seals 116-11 valves 116-11 valves, leak test 116-11 valves, removing/installing 116-6 Cylinder head removal and installation general information 113-1 cylinder head, removing/installing (4cylinder engine) 113-1 cylinder head (6-cylinder engine), removing/installing 113-10

Dashboard See Interior trim Deck lid See Trunk lid Defogger See Heating Differential See Final drive DISA (dual resonance intake system) See Fuel injection See also Engine-general DME (digital motor electronics) See Ignition system See also Fuel injection

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INDEX WARNING Your common sense, good judgement, and general alertness are crucial to safe and successful service work . Befcre attempting any work on your BMW, read the warnings and cautions on page vi¡ and the copyright page at the front of the manual . Review these warnings and cautions each time you prepare to work on your BMW . Please also read any warnings and cautions that accompany the procedures in the manual .

Door glass See Door windows Door windows general information 512-1 front door window (2-door models) adjusting 512-7 removing/installing 512-5 front door window (4-door models) initíalizing 512-1 removing/installing 512-2 rear door window (4-door models) removing/installing 512-4 fixed glass, removing/installing 5124 rear vent window or vent latch, replacing (2-door models) 512-11 window regulator and motor, removing/installing 512-12 window regulator service 512-12 Door check See Doors Door handle See Central locking and anti-theft Door panel See Doors Doors general information 411-1 door adjustment 411-2 door check, replacing 411-2 door panels 411-3 doors 411-1 front or rear door, removing/installing 411-1 front door panel, removing/installing 411-3 rear door panel, removing/installing 411-4 rear side panel, removing/installing (two-door model) 411-4 Drive axle See Rear suspension Driveability troubleshooting See Engine-general Driveshaft general information 260-1 center bearing assembly, replacing 260-6 driveshaft, aligning 260-3 driveshaft, installing 260-4

Driveshaft (cont .) driveshaft, removing 260-4 driveshaft service 260-3 flex-disc, replacing 260-5 front centering guide, replacing 260-7 guibo See flex-disc troubleshooting 260-1

ECM (engine control module) pin assignment See Fuel injection Electrical circuit See Electrical system-general Electrical component locations general information 610-1 auxíliary relay panel 610-2 component location table 610-9 component locations 610-3 fuse position tables 610-19 fuse positions 610-1 relay positions 610-2 splice panel, left 610-2 splice panel, right 610-3 Electrical system-general general information 600-1 continuity, checking 600-5 electrical test equipment 600-2 safety precautions 600-1 short circuits 600-5 short circuit, testing with ohmmeter 600-6 short circuit, testing with voltmeter 600-6 troubleshooting 600-3 voltage, measuring 600-4 voltage and polarity 600-1 voltage and voltage drops 600-4 voltage drop, testing 600-4 wiring codes and abbreviations 600-2 wiring diagrams 600-2 wiring, fuses and relays 600-1 Electrical wiring diagrams general information ELE-1 wiring diagrams ELE-2 ABS ELE-117 ABS/AST ELE-120 airbag (supplemental restraint system) ELE-140 air conditioning and heating ELE129 anti-theft (Alpine) system ELE-144 anti-theft (EWS II) ELE-150 body computer module ELE-176 charging system ELE-67 convertible top ELE-253 cruise control ELE-112 data link connector ELE-86 engine cooling ELE-94 engine management ELE-70 exterior lights ELE-194 ground distribution ELE-35 headlights/foglights ELE-180

Electrical wiring diagrams (cont .) heated seats ELE-245 horns ELE-153 instrument panel ELE-165 interior lights/illumination ELE-211 lumbar control ELE-247 on-board computer ELE-173 park ventilation ELE-139 power distribution ELE-2 power door locks ELE-226 power mirrors ELE-241 power seats ELE-243 power sunroof ELE-248 power windows ELE-231 radio/cassette/CD/speakers ELE255 rear window defogger ELE-160 shift interlock ELE-110 starting ELE-63 transmission electronics ELE-96 warning systems`. chimes ELE-178 wiper/washer ELE-154 Emergencies See Fundamentals for the do-ityourself owner Engine-general general information 100-1 air flow measurement and vacuum leaks 100-12 basic engine settings 100-11 basic requirements 100-11 battery voltage 100-12 connecting rods and pistons 100-1 cooling system 100-5 cylinder block and crankshaft 100-1 cylinder compression, checking 100-6 cylinder head and valvetrain 100-2 DISA (dual resonance intake system) 100-3,130-3 driveability troubleshooting 100-8 engine management system 100-3 fuel delivery 100-5 fuel supply 100-14 ground connections 100-13 ignition 100-5 lubrication system 100-5 mechanical troubleshooting 100-5 on-board diagnostics (OBD) 100-8 oxygen sensors 100-11 preventive maintenance 100-11 VANOS (variable valve timing) 100-2 warnings and cautions 100-5 wiring and harness connections 10013 Engine control module (ECM) See Fuel injection Engine removal and installation general information 110-1 engine, removing/installing (4-cylinder engines) 110-1 engine, removing/installing (6-cylinder engines) 110-4 Engine coolant temperature (ECT) sensor See Fuel injection Engine hood See Fenders, engine hood

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INDEX Evaporator See Air conditioning EWS (Electronic immobilization system) 515-8 Exhaust system See also Maintenance program general information 180-1 exhaust manifolds, removingAnstalling 180-5 exhaust system, removing/installing 180-3 Expansion valve See Air conditioning Exterior lighting general information 630-1 center brake light housing, replacing (4-door and coupe models) 630-5 foglight assembly, removing/installing 630-3 front turn signal assembly, removing/ installing 630-4 headlight assembly, removing/ installing 630-2 headlight bulb, replacing 630-1 license plate light, removing/installing 630-6 side marker lights 630-4 taillight assembly, removing/installing 630-5 taillight bulbs, replacing 630-4 Exterior trim, bumpers general information 510-1 BMW embiem, removing/installing 510-7 body side molding, replacing -7 bumper height, adjusting 510-6 front bumper, removing/installing 5103 front bumper impact absorber, replacing 510-4 front panel, removing/installing 510-7 outside rear view mirrors 510-1 mirror housing, removing/installing 510-1 mírror, removing/installing 510-2 mirror glass, replacing 510-1 radiator grille, removing/installing 510-7 rear bumper, removingfinstalling 5104 rear bumper impact absorber, replacing 510-4

F Fenders, engine hood general information 410-1 front fenders 410-1 front fender, removing/installing 410-1 hood aligning 410-4 hood, raising to service position 410-2 hood release cable and latches, adjusting 410-4 hood, removing/installing 410-3

Final drive general information 331-1 final drive se rvice 331-1 flange oil sea¡, replacing 331-2 input shaft oil sea¡, replacing 331-3 oil, draining/filling 331-1 oil seals 331-1 removing/installing 331-3 Final drive carrier See Rear suspension Firing order See Ignition system Flex disc See Driveshaft Fluids and lubricants See Maintenance program Foglight See Exterior lighting Front suspension general information 310-1 ball joint See outer control arm ball joint control arm, removing/installing 310-5 control arm bushing, replacing 310-7 control arms 310-5 front wheel bearing, replacing 310-8 front wheel bearings 310-8 outer control arm ball joint, replacing (except M3) 310-6 ride height 310-4 shock absorbers and springs 310-2 stabilizer bar 310-9 stabilizer bar, removing/installing 310-9 strut assembly, disassembling/ assembling 310-4 strut assembly, removing/installing 310-2 subframe crossmember 310-9 subframe crossmember, removing/ installing 310-9 Fuel injection general information 130-2 basic engine settings 130-2 principies of operatínn 130-2 Bosch DME Ml .7 component tests and repairs 130-14 air floiv sensor, testing/replacing 130-14 engine coolant temperature (ECT) sensor, testing/replacing 130-15 ¡dle speed control valve, testing/ replacing 130-16 throttle position sensor (TPS), testing/replacing 130-16 Bosch DME M3 .1 and M3 .3 .1 component tests and repairs 130-17 engine coolant temperature (ECT) sensor, testing/replacing 130-18 ¡dle speed control valve, replacing 130-21 ¡dle speed control valve, testing 13020 intake air temperature (IAT) sensor, testing/replacing 130-19 mass air flow sensor 130-17

Bosch DME M3 .1 and M3 .3 .1 (cont) mass air flow sensor (hot film) testing/replacing 130-18 mass air flow sensor (hot wire) testing/replacing 130-17 throttle position sensor (TPS), testing/replacing 130-19 Bosch DME M5 .2 component replacement 130-21 engine coolant temperature (ECT) sensor, replacing 130-22 ldle speed control valve, replacing 130-23 intake air temperature (IAT) sensor, replacing 130-22 mass air flow sensor, replacing 13022 throttle position sensor (TPS), replacing 130-22 DISA (dual resonance intake system) 130-3 ECM pin assignments 130-26 electrical checks and component testing 130-7 engine control module(ECM), accessing 130-26 fuel delivery tests 130-9 fuel pressure regulator response to engine load, testing 130-11 fuel pressure regulator 130-13 fuel pressure regulator, replacing (fuel rail mount) 130-13 fuel pressure regulator, replacing (under car mount) 130-14 fuel pump relay, testing 130-7 fuel rail and injectors, checking 130-11 fuel rail and injectors, replacing 13012 fuel delivery tests (cont .) operatíng fuel pump for tests 130-9 relieving fuel pressure and connecting fuel pressure gauge 130-10 residual fuel pressure, testing 130-10 main relay, testing 130-7 on-board diagnostics (OBD) and fault diagnosis 130-4 oxygen sensor, testing (Bosch systems only) 130-8 secondary air injection 130-5 Siemens MS 41 .1 component replacement 130-23 engine coolant temperature (ECT) sensor, replacing 130-25 ¡dle speed control valve, replacing 130-26 lntake air temperature (IAT) sensor, replacing 130-25 mass air flow sensor, replacing 13025 throttle position sensor (TPS), replacing 130-26 warnings and cautions 130-6 Fuel filter See Maintenance program

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Fuel pressure regulator See Fuel injection Fue] pump general information 160-1 electrical tests 160-7 power consumption, testing 160-7 delivery tests160-8 delivery volume, testing g 160-9 electrical circuit, checking 160-7 fuse and relay 160-6 level sender See pump/fuel leve¡ sender operating fuel pump for tests 160-6 pump/fuel level sender (left side), removing/installing 160-6 pump/fuel leve¡ sender (right side), removing/installing 160-5 relieving fuel pressure and connecting fue¡ pressure gauge 160-8 Fuel tank and lines general information 160-1 draining 160-2 evaporative control system 160-4 leve¡ senders, testing 160-5 removing/installing 160-3 Fundamentals for the do-it-yourself owner general information 010-1 advice for the beginner 010-4 cleanliness 010-4 electrical testing 010-6 gaskets and seals 010-5 non-reusable fasteners 010-5 planning ahead 010-4 tightening fasteners 010-5 wire repairs 010-6 buying parts 010-6 genuine BMW parts 010-6 information you need to know 010-7 non-returnable parts 010-7 emergencies 010-11 brake fluid leve¡ 010-13 car will not start 010-11 changing a tire 010-11 check engine warning light 010-13 dim Iights 010-13 jump starting car 010-12 low o]I pressure 010-13 overheating 010-12

Emergencies (cont .) spare parts kit 010-14 towing 010-13 getting started 010-2 lifting the car 010-3 raising car safely 010-3 safety 010-2 working under car safely 010-4 how to use this manual 010-2 warnings, cautions and notes 010-2 service 010-7 tools 010-7 basic tool requirements 010-8 BMW special tools 010-11 feeler gauges 010-10 jack stands 010-9 oil change equipment 010-9 torque wrench 010-10 volt-ohm meter (VOM) or Multimeter 010-10 Fuses See Electrical component locations

G Gaskets See Fundamentals for the do-ityourself owner Gearshift See Gearshift linkage Gearshift linkage general information 250-1 automatic shiftlock, checking function 250-5 automatic transmission gearshift 2503 gear position/neutral safety switch, replacing (automatic transmission) 250-4 gearshift lever, installing (manual transmission) 250-2 gearshift lever, removing (manual transmission) 250-1 gearshift mechanism, adjusting (automatic transmission) 250-3 manual transmission gearshift 250-1 shift interlock, checking function (automatic transmission) 250-6 Glass See Door windows Glove compartment See Interior trim Grille See Exterior trim, bumpers Guibo (flex disc) See Driveshaft

Handle, door See Doors Hardtop See Body-general Headlight See Exterior lighting Headlight switch See Switches and electrical accessories Heater box See Heating Heater core See Heating Heater valve See Heating Heating general information 640-1 air distribution motors 640-9 air distribution motor, replacing (rotary knob) 640-10 blower motor, removing/installing 640-1 blower motor resistor pack, replacing 640-3 control head 640-7 removing/installing (digital-display) 640-8 removing/installing (rotary knob) 640-7 control module removing/installing (digital-display) 640-8 removing/installing (rotary knob) 640-8 heater box, removing 640-4 heater core, replacing 640-6 heater core temperature sensor, replacing 640-7 heater valve, replacing 640-3 rear window blower (convertible models) 640-10 reas window defogger 640-10 sensor fan for interior temperature, replacing 640-9 warnings and cautions 640-11 Hood See Fenders, engine hood

Idle speed See Maintenance program Idle speed control valve See Fuel injection Ignition switch See Switches and electrical accessories

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INDEX Ignition system general information 120-1 basic troubleshooting principies 120-3 camshaft position (CMP) sensor 1206 camshaft positíon (CMP) sensor, replacing (4-cylinder engine) 120-6 camshaft position (CMP) sensor, replacing (6-cylinder engines) 120-7 checking for spark 120-3 crankshaft position/rpm sensor 120-5 crankshaft position/rpm sensor, testing/replacing (front mounted sensor) 120-6 crankshaft positíon/rpm sensor, testing (rear mounted sensor) 120-6 disabling ignition system 120-2 ignition coil, testing and replacing (4cylinder engines) 120-3 ignition coil, testing and replacing (6cylinder engines) 120-4 ignítion firing order 120-7 ignition system diagnostics 120-3 ignition system schematics 120-7 ignition system service 120-3 knock sensors, replacing 120-7 warnings and cautions 120-2 Inspectíon I and Inspection II See Maintenance program Instrument panel See interior trim Instruments general information 620-1 instrument cluster, removinglinstalling 620-1 instrument cluster, self-testing 620-1 instrument cluster bulbs, replacing 620-2 multi-information display (MID), 620-4 multi-information display (MID), removing/installing 620-4 odometer coding plug, replacing 6202 vehicle speed sensor, replacing 620-3 Intake manifold 4-cylinder engíne, removing 113-3 6-cylinder engine, removing 113-11 See also Cylinder head removal and installation Intake air temperature sensor See Fuel injection Interior trim general information 513-1 center console, removing/installing 513-1 dashboard, removing/installing 513-3 glove compartment, removing/ installing 513-2 lower left dash panel, removing/ installing 513-2

K Knock sensor See Ignition system

L Leather upholstery See Maíntenance program Leve¡ sender See Fuel pump Lubrication system general information 119-1 oil pan, removing/installing (4-cylinder engines) 119-2 oil pan, removing/installing (6-cylinder engine, 1992 models) 119-4 oil pan 119-2 oil pan, removing/installing (6-cylinder engine, 1993 and later models) 119-6 oil pressure, checking 119-1 oil pressure warning system, testing 119-2 oil pump 119-8 oil pump, removing/installing (4-cylinder engine) 119-8 oil pump, removing/installing (6-cylinder engine) 119-9 troubleshooting 119-1

M Maíntenance program general information 020-2 accelerator and throttle linkage 020-13 air filter, replacing 020-11 automatic transmission fluid 020-8 automatic transmission service 020-18 battery, checking and cleaning 020-12 battery, replacing 020-12 BMW service indicator 020-2 body and hinges, lubricating 020-19 brake fluid 020-9 brake fluid, replacing 020-17 brake pad/rotor wear, checking 020-17 brake system, inspecting 020-17 clutch fluid, checking 020-19 cooling system service 020-14 drive axle joint boots, inspecting 020-19 engine coolant (anti-freeze) 020-9 engine drive belts 020-13 engine oil, checking leve¡ 020-9

Maintenance program (cont.) engine oil and filter, changing 020-9 engine oil service 020-9 exhaust system, inspecting 020-18 exterior washing 020-20 final drive gear oil 020-9 final drive oil level, checking 020-18 front suspension and steering linkages, inspecting 020-18 fuel filter, replacing 020-16 fuel tank and fuel lines, inspecting 020-19 ¡dle speed 020-12 inspection I and inspection 11 020-2 interior care 020-20 leather upholstery and trim 020-20 maintenance tables 020-3 manual transmission fluid, checking and filling 020-18 manual transmission fluid 020-8 manual transmission service 020-18 oxygen sensors 020-15 parking brake, checking 020-17 polishing 020-20 poly-ribbed belt, replacing 020-13 power steering fluid 020-9 power steering fluid, checking leve¡ 020-14 rear suspension, inspecting 020-18 resetting service indicator 020-3 seat belts 020-20 spark plugs, replacing 020-11 special cleaning 020-20 tires, checking inflation pressure 020-17 tires, rotating 020-17 v-belt, replacing 020-13 washing chassis 020-20 waxing 020-20 windshield wiper blade maintenance 020-19 wheels, aligníng 020-17 Manual transmission See also Maintenance program See also Transmission-general general information 230-1 back-up light switch, replacing 230-2 input shaft sea¡, replacing (transmission installed) 230-5 output shaft sea¡, replacing (transmission installed) 230-4 selector shaft sea¡, replacing (transmission installed) 230-3 transmission fluid, replacing 230-2 transmission fluid level, checking 2302 transmission fluid service 230-1 transmission removal and installation 230-5 transmission, removing/installing 2306 transmission service 230-2 Mass air flow sensor See Fuel Injection

Jump startíng 010-12

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

INDEX WARNING Your common sense, good judgement, and general alertness are crucial to safe and successful service work. Before attempting any work on your BMW, read the warnings and cautions on page vi¡ and the copyright page at the front of the manual . Review these warnings and cautions each time you prepare to work on your BMW. Please also read any warnings and cautions that accompany the procedures in the manual .

Master cylinder See Brakes See also Clutch Mechanical troubleshooting See Engine-general Microfilter See Air conditioning Mirror See Exterior trim, bumpers Muffler See Exhaust system Multi-information display (MID) See Instruments

N Neutral safety switch See Gearshift linkage

O Oil, changing See Maintenance program Oil pan See Lubrication system Oil pressure See Lubrication system Oil pump See Lubrication system On-board diagnostics (OBD) See Engine-general See also Fuel injection See also Ignition system On-board trip computer See Multi-information display 620-4 Oxygen sensor See Engine-general See also Fuel injection See also Maintenance program

P Parking brake See Brakes See also Maintenance program Parts See Fundamentals for the do-ityourself owner Poly-ribbed belt See Maintenance program Power steering See Steering and wheel alignment Power steering (luid See Maintenance program

R Radiator See Cooling system Radio general information 650-1 audio system 650-1 radio connector 650-6 removing/installing 650-2 speakers door panel speaker, removing/ installing 650-5 left footwell speaker, removing/ installing 650-3 rear speaker, removing/installing 650-5 right footwell speaker, removing/ installing 650-4 Rear suspension See also Maintenance program general information 330-1 coil spring, removing/installing 330-4 CV boot, replacing 330-8 drive axle, removing/installing 330-6 drive axles 330-6 final drive carrier 330-12 final drive carrier, removing/installing 330-12 lower control arm, removing/installing 330-12 rear shock absorber, removing/ installing 330-3 rear suspension arms 330-9 ride heíght 330-1 shock absorbers and springs 330-2 trailing arm, removing/installing 330-10 trailing arm bushing, replacing 330-11 upper control arm, removing/installing 330-12 rear wheel bearing, replacing 330-5 rear wheel bearings 330-4 Rear view mirror See Exterior trim, bumpers Receiver/drivr See Air conditioning Relays See Electrical component locations

Ride height See Front suspension or Rear suspension Ring antenna See Central locking and anti-theft Roof See Convertible top See also Sunroof Roundel See Exterior trim, bumpers

S Seat belts general information 720-1 automatic front seat belt lock tensioners 720-2 center rear lap-belt, removing/ installing 720-5 front seat belt reel, removing/installing 720-3 mechanical spring tensioner, disarming 720-2 rear seat belt, removing/installing (fixed seat back models) 720-4 rear seat belt, removing/installing (fold-down seat back models) 720-5 Seats general information 520-1 front seats 520-1 manual front seat assembly 520-3 power front seat assembly 520-4 removing/installing 520-1 rear seats 520-5 rear seat cushion and backrest, removing/installing (fixed seat back models) 520-5 rear seat cushion and backrest, removing/installing (fold-down seat back models) 520-5 rear seat backrest side section, removing/installing (fold-down seat back models) 520-6 Shift interlock See Gearshift linkage Shift lever See Gearshift linkage Shíftlock See Gearshift linkage Shock absorber See Front suspension See also Rear suspension Side-impact airbag See Airbag system (SRS) Slave cylinder See Clutch Service indicator See Maintenance program Solenoid See Battery, starter, alternator Spark See Ignition system Spark plugs See Maintenance program

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INDEX Speakers See Radio SRS (Supplemental restraint system) See Airbag system (SRS) Starter See Battery, starter, alternator Steering and wheel alignment general information 320-1 caster and camber 320-5 front toe-in and toe difference angle 320-6 outer tie rod end, replacing 320-4 power steering pump, removing/ installing 320-2 power steering system 320-2 power steering system, bleeding/filling 320-3 rear toe-in 320-6 steering gear 320-3 steering gear rack, removing/installing 320-3 steering wheel 320-1 steering wheel, removing/installing 320-1 tie rod, replacing 320-5 wheel alignment 320-5 wheel alignment specifications 320-6 Steering gear See steering and wheel alignment Strut See Front suspension Subframe See Front suspension Sunroof general information 540-1 motor, removing/installing 540-3 panel, adjusting 540-2 panel, emergency closing 540-2 Suspension, front See Front suspension Suspension, rear See Rear suspension Suspension, steering and brakes general information 300-1 al¡ season traction (AST) 300-4 antilock brake system (ABS) 300-2 brakes 300-2 front suspension 300-1 integrated systems 300-2 M3 suspension and brakes 300-7 steering 300-2 rear suspension 300-2 suspension and steering troubleshooting 300-7 tires and wheels 300-2

Switches and electrical accessories general information 612-1 dome light, rear map lights, trunk light, replacing bulbs 612-7 hazard warning switch, replacing 612-5 headlight switch, replacing 612-5 foglight switch, replacing 612-5 ignition electrical switch, replacing 612-3 ignition lock cylinder, replacing 612-4 ignition switch assembly 612-3 outside mirror switch, replacing 612-6 power window switch, replacing 612-5 turn signal switch and wiper switch, removing/installing 612-1 wiper switch See turn signal and wiper switch

Trim, interior See Interior trim Trunk lid general information 412-1 trunk lid, 412-1 trunk lid, aligning 412-1 trunk lid, removing/installing 412-1 trunk lid support strut, removing/ installing 412-2

Taillight See Exterior lighting Thermostat See Cooling system Throttle position sensor (TPS) See Fuel injection Throw-out bearing See Clutch Tie rod See Steering and wheel alignment Tires See Suspension, steering and brakes-general See also Maintenance program Timing chain See Camshaft timing chain Toe-in See Steering and wheel alignment Tools See Fundamentals for the do-ityourself owner Torque convector See Automatic transmission Towing See Fundamentals for the do-ityourself owner Traction control See also Suspension, steering and brakes-general Trailing arm See Rear suspension Transmission-general See also Automatic transmission See also Manual transmission general information 200-1 automatic transmission 200-1 manual transmission 200-1 transmission ID codes 200-2 Transmission fluid See Maintenance program See also Automatic transmission Transmission input shaft See Manual transmission Transmission output shaft See Manual transmission

U Upholstery See Maintenance program U-joints See Driveshaft

V-belt See Maintenance program Vacuum booster See Brakes Vacuum leaks See Engine-general Valve guides See Cylinder head and valvetrain Valve seals See Cylinder head and valvetrain Valve seats See Cylinder head and valvetrain Valves See Cylinder head and valvetrain Valvetrain See Cylinder head and valvetrain VANOS (variable valve timing) See Camshaft timing chaín See also Engine-general Vehicle identification number (VIN) See Fundamentals for the do-ityourself owner Vehicle speed sensor See Instruments Ventilation See Air conditioning See also Heating Voltage regulator See Battery, starter, alternator Voltage tests See Electrical system-general

W Warnings vi¡ Washer fluid pump See Wipers and washers Washers See Wipers and washers Water pump See Cooling system Waxing See Maintenance program

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina

INDEX WARNING Your common sense, good judgement, and general alertness are crucial to safe and successful service work . Before attempting any work on your BMW, read the warnings and cautions on page vi¡ and the copyright page at the front of the manual . Review these warnings and cautions each time you prepare to work on your BMW . Please also read any warnings and cautions that accompany the procedures in the manual .

Wheel bearings See Front suspension or Rear suspension Wheel, steering See Steering and wheel alignment Wheels See Maintenance program Window regulator See Door windows Window switch See Switches and electrical accessories Windows, door See Door windows Windshield wipers and washers See Wipers and washers See also Maintenance program Wiper motor See Wipers and washers

Wipers and washers general information 611-1 washer fluid leve¡ sensor, replacing (models with check control) 611-10 washer (luid pump, replacing 611-9 washerfluid reservoir, replacing 611-9 windshield spray nozzle, removing/ installing 611-9 windshield wiper assembly, removing/ installing (4-door models) 611-3 windshield wiper assembly, removing/ installing (2-door models) 611-5 wiper arms, removing/installing 611-2 wiper blade inserts, replacing 611-2 wiper blade cleaning problems 611-1 wiper blades, replacing 611-1 wiper motor, removing/installing 611-8 Wiring diagrams See Electrical wiring diagrams

Z ZAE See Airbag system (SRS) ZKE See Central body electronics ZVM See Central locking

Versión electrónica licenciada a Hernan Fulco / hfulco@iplan.com.ar / tel: 54(11)4855-3088 Buenos Aires // Argentina