BMW 3- & 5-Series Service And Repair Manual

BMW 3- & 5-SeriesService and Repair ManualA K LeggLAE MIMIand Larry Warren(1948-256-11AA3)Models covered3-Series (E30)316 (83 to 88), 316i (88 to 91), 318i (83 to 91), 320i (87 to 91), 325i (87 to 91).Also Touring and Convertible versions of these models5-Series (E28)518 (81 to 85), 518i (85 to 88), 525i (81 to 88), 528i (81 to 88), 535i (85 to 88), M535i (85 to 88)5-Series (E34)518i (90 to 91), 520i (88 to 91), 525i (88 to 91), 530i (88 to 91), 535i (88 to 91)Engines covered1596 cc, 1766 cc, 1795 cc, 1990 cc, 2494 cc, 2788 cc, 2986 cc & 3430 ccDoes not cover Diesel, dohc or V8 engines, or four-wheel-drive models Haynes Publishing 1997A book in the Haynes Service and Repair Manual SeriesABCDEFGHIJKLMNOPQRST123All rights reserved. No part of this book may be reproduced or transmittedin any form or by any means, electronic or mechanical, includingphotocopying, recording or by any information storage or retrieval system,without permission in writing from the copyright holder.Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,SomersetBA22 7JJ, EnglandHaynes PublishingSparkford, Nr Yeovil, Somerset BA22 7JJ, EnglandHaynes North America, Inc861 Lawrence Drive, Newbury Park, California 91320, USAISBN 1 85960 236 3Editions Haynes S.A.147/149, rue Saint Honoré, 75001 PARIS, FranceBritish Library Cataloguing in Publication DataA catalogue record for this book is available from the British Library.Haynes Publishing Nordiska ABBox 1504, 751 45 Uppsala, Sweden

ContentsLIVING WITH YOUR BMWIntroductionPage0 4Safety First!Page0 6Anti-theft audio systemPage0 7Instrument panel language displayPage0 7Jacking, towing and wheel changingPage0 8Jump startingPage0 9Identifying leaksPage0 10Routine Maintenance and ServicingPage1 1Lubricants and fluidsPage1 3Maintenance schedulePage1 4Weekly checksPage1 7Every 6000 milesPage1 11Every 12 000 milesPage1 16Every 24 000 milesPage1 23Every 60 000 milesPage1 26Roadside RepairsROUTINE MAINTENANCE

ContentsREPAIRS & OVERHAULEngine and Associated SystemsIn-car engine repair proceduresPage 2A 1General engine overhaul proceduresPage 2B 1Cooling, heating and air conditioning systemsPage3 1Fuel and exhaust systemsPage4 1Engine electrical systemsPage5 1Engine management and emission control systemsPage6 1TransmissionManual transmissionPage 7A 1Automatic transmissionPage 7B 1Clutch and drivelinePage8 1Page9 1Page10 1Page11 1Body electrical systemsPage12 1Wiring DiagramsPage 12 10BrakesBraking systemSuspensionSuspension and steering systemsBody EquipmentBodywork and fittingsElectricalREFERENCEMOT Test ChecksChecks carried out from the driver’s seatPageREF 1Checks carried out with the vehicle on the groundPageREF 2Checks carried out with the vehicle raisedPageREF 3Checks carried out on your vehicle’s exhaust emission systemPageREF 4Tools and Working FacilitiesPageREF 5General Repair ProceduresPageREF 8Fault FindingPageREF 9Conversion factorsPage REF 17Automotive chemicals and lubricantsPage REF 18Buying spare parts and vehicle identification numbersPage REF 19Glossary of Technical TermsPage REF 20IndexPage REF 25

0 4IntroductionIntroduction to the BMW 3- and 5-SeriesThe E30 3-Series range first becameavailable in the UK in March 1983, andcontinued in production until April 1991, whenthe revised E36 3-Series range (not coveredby this manual) was introduced. Convertibleand Touring (Estate) models were introducedfor 1988, and these models have continued inE30 form to date.The E28 5-Series models were introducedin October 1981, and were superseded inJune 1988 by the revised E34 5-Series range,Touring versions of which became availablefrom March 1992. Throughout this manual,E28 models are also referred to as “oldshape”, while E34 models are designated“new-shape”.The models covered by this manual areequipped with single overhead cam in-linefour- and six-cylinder engines. Early 316 and518 models are fitted with carburettors, but allother models are fitted with fuel injectionsystems. Transmissions are a five-speedmanual, or three- or four-speed automatic.The transmission is mounted to the back ofthe engine, and power is transmitted to thefully-independent rear axle through a twopiece propeller shaft. The final drive unit isbolted solidly to a frame crossmember, anddrives the rear wheels through driveshaftsequipped with inner and outer constantvelocity joints.The front suspension is of MacPhersonstrut type, with the coil spring/shock absorberunit making up the upper suspension link. Therear suspension is made up of coil springover-shock absorber struts, or coil springsandconventionalshockabsorbers,depending on model.The brakes are disc type at the front, witheither drums or discs at the rear, dependingon model. Servo assistance is standard on allmodels. Some later models are equipped withan Anti-lock Braking System (ABS).All models are manufactured to fine limits,and live up to the BMW reputation of qualityworkmanship. Although many of the modelscovered by this manual appear complex atfirst sight, they should present no problems tothe home mechanic.Note for UK readersThe greater part of this manual wasoriginally written in the USA. Some of thephotographs used are of American-marketmodels, but the procedures given are fullyapplicable to right-hand-drive models (or havebeen amended where necessary).BMW 320i Saloon (E30)AcknowledgementsThanks are due to Champion Spark Plug,who supplied the illustrations showing sparkplug conditions. Thanks are also due toSykes-Pickavant Limited, who provided someof the workshop tools, and to all those peopleat Sparkford who helped in the production ofthis manual. Technical writers whocontributed to this project include RobertMaddox, Mark Ryan and Mike Stubblefield.We take great pride in the accuracy ofinformation given in this manual, butvehicle manufacturers make alterationsand design changes during the productionrun of a particular vehicle of which they donot inform us. No liability can be acceptedby the authors or publishers for loss,damage or injury caused by anyerrors in, or omissions from, theinformation given.Project vehiclesThe main project vehicle used in thepreparation of this manual for the UK marketwas a 1988 BMW 318i with an M40/B18engine.

IntroductionBMW 325i Touring (E30)BMW 325i Convertible (E30)BMW 518i (E28)BMW 535i (E34)0 5

0 6Safety First!Working on your car can be dangerous.This page shows just some of the potentialrisks and hazards, with the aim of creating asafety-conscious attitude.General hazardsScalding Don’t remove the radiator or expansiontank cap while the engine is hot. Engine oil, automatic transmission fluid orpower steering fluid may also be dangerouslyhot if the engine has recently been running.Burning Beware of burns from the exhaust systemand from any part of the engine. Brake discsand drums can also be extremely hotimmediately after use.Crushing When working under or neara raised vehicle,alwayssupplement thejack with axlestands, or usedrive-onramps.Neverventureunder a car whichis only supported by a jack. Take care if loosening or tightening hightorque nuts when the vehicle is on stands.Initial loosening and final tightening shouldbe done with the wheels on the ground. Mains voltage is also dangerous. Makesure that any mains-operated equipment iscorrectly earthed. Mains power points shouldbe protected by a residual current device(RCD) circuit breaker.Fume or gas intoxication Exhaust fumes arepoisonous; they oftencontain carbonmonoxide, which israpidly fatal if inhaled.Never run theengine in aconfined spacesuch as a garagewith the doors shut. Fuel vapour is alsopoisonous, as are the vapours from somecleaning solvents and paint thinners.Poisonous or irritant substances Avoid skin contact with battery acid andwith any fuel, fluid or lubricant, especiallyantifreeze, brake hydraulic fluid and Dieselfuel. Don’t syphon them by mouth. If such asubstance is swallowed or gets into the eyes,seek medical advice. Prolonged contact with used engine oil cancause skin cancer. Wear gloves or use abarrier cream if necessary. Change out of oilsoaked clothes and do not keep oily rags inyour pocket. Air conditioning refrigerant forms apoisonous gas if exposed to a naked flame(including a cigarette). It can also cause skinburns on contact.FireAsbestos Fuel is highly flammable; fuel vapour isexplosive. Don’t let fuel spill onto a hot engine. Do not smoke or allow naked lights(including pilot lights) anywhere near avehicle being worked on. Also beware ofcreating sparks(electrically or by use of tools). Fuel vapour is heavier than air, so don’twork on the fuel system with the vehicle overan inspection pit. Another cause of fire is an electricaloverload or short-circuit. Take care whenrepairing or modifying the vehicle wiring. Keep a fire extinguisher handy, of a typesuitable for use on fuel and electrical fires. Asbestos dust can cause cancer if inhaledor swallowed. Asbestos may be found ingaskets and in brake and clutch linings.When dealing with such components it issafest to assume that they contain asbestos.Electric shock Ignition HTvoltage can bedangerous,especially topeople with heartproblems or apacemaker. Don’twork on or near theignition system withthe engine running orthe ignition switched on.Special hazardsHydrofluoric acid This extremely corrosive acid is formedwhen certain types of synthetic rubber, foundin some O-rings, oil seals, fuel hoses etc, areexposed to temperatures above 4000C. Therubber changes into a charred or stickysubstance containing the acid. Once formed,the acid remains dangerous for years. If itgets onto the skin, it may be necessary toamputate the limb concerned. When dealing with a vehicle which hassuffered a fire, or with components salvagedfrom such a vehicle, wear protective glovesand discard them after use.The battery Batteries contain sulphuric acid, whichattacks clothing, eyes and skin. Take carewhen topping-up or carrying the battery. The hydrogen gas given off by the batteryis highly explosive. Never cause a spark orallow a naked light nearby. Be careful whenconnecting and disconnecting batterychargers or jump leads.Air bags Air bags can cause injury if they go offaccidentally. Take care when removing thesteering wheel and/or facia. Special storageinstructions may apply.Diesel injection equipment Diesel injection pumps supply fuel at veryhigh pressure. Take care when working onthe fuel injectors and fuel pipes.Warning: Never expose the hands,face or any other part of the bodyto injector spray; the fuel canpenetrate the skin with potentially fatalresults.Remember.A few tipsDODON’T Do use eye protection when using powertools, and when working under the vehicle. Don’t attempt to lift a heavy componentwhich may be beyond your capability – getassistance. Do wear gloves or use barrier cream toprotect your hands when necessary. Do get someone to check periodicallythat all is well when working alone on thevehicle. Do keep loose clothing and long hair wellout of the way of moving mechanical parts. Do remove rings, wristwatch etc, beforeworking on the vehicle – especially theelectrical system. Do ensure that any lifting or jackingequipment has a safe working load ratingadequate for the job. Don’t rush to finish a job, or takeunverified short cuts. Don’t use ill-fitting tools which may slipand cause injury. Don’t leave tools or parts lying aroundwhere someone can trip over them. Mopup oil and fuel spills at once. Don’t allow children or pets to play in ornear a vehicle being worked on.