Checking/Correcting Engine Oil Level
Requirements: Car on level surface.
Add oil to raise level to max. mark at most.
Amount of oil between min. and max. marks:
1.5 ltr. (3 pints).
Refer to Service Information of Group 11 for approved oils.


11 000 000

Checking/Correctiong Manual Transmission Oil Level
Unscrew oil filter plug.
Add oil to raise level to lower edge of filter opening.
Refer to Service Information of Group 23 for approved oils.
Installation: Check filler plug, replacing if necessary.
Tightening torque¹).


¹) See Specifications of Groups 23 and 24
¹) See Specifications of Groups 23 and 24

Checking/Correcting Automatic Transmission Oil Level
Requirments: Car on level surface.
Transmission at operating temperature.
Selector lever at "P".
Engine running at idle speed.
Amount of oil between min. and max. marks:
Flat oil pan = approx. 0.25 ltr. (0.5 pints)
Deep oil pan = approx. 0.40 ltr. (0.8 pints)
Important: Never wipe off dipstick with a cloth
losing lint.
Refer to Service Information of Group 24 for approved ATF.
Add ATF through funnel 24 0 080.


24 00 000

Checking Power Steering Oil Level
With engine stopped, unscrew winged nut and take off tank cover.
Oil level should be approx. 5 mm (0,.2´´) above mark on tank wall.
Start engine and, if necessary, add oil until level agrees with mark,
Refer to Service Information of Group 32 for approved oils.


32 00 000

Checking/Correcting Final Drive Oil Level
Unscrew oil filler plug.
Add oil to raise level to lower edge of filler opening.
Refer to Service Information of Group 33 for approved oils.
Installation: Check seal, replacing if necessary.
Tightening torque¹).


33 00 000
¹) See Specifications of Group 33

Checking/Correctiong Brake Fluid Level
Brake fluid level must be between min. and max. marks
in transparent tank for brake system.
Add brake fluid to raise level to max. mark.
Refer to Service Information of Group 34 for approved brake fluids.
Inportant: Replace brake fluid annually.


34 00 000

Checking/Correcting Battery Acid Level
Lift off battery cover and unscrew caps.
Acid level should be approx. 5 mm (0.2´´) above upper edge of
plates in each cell or up to level mark visible in opening.
Add distilled water, if level is too low.
Keep top surface of battery dry and clean.
Important: Be careful not to get acid and lead
oxide from battery poles on clothing.
Never work with an open flame near batteries.
Danger of explosion!

Checking Coolant Level and Concentration
Add coolant to raise level to 2 cm (0.8´´) below
radiator cap at most.
Check antifreeze concentration.
All year protection down to -25°C (-13°F).
Refer to Service Information of Group 17 for
approved antifreezes (longterm) and corrosion inhibitors.


17 00 000

Checking/Correcting Fluid Level in Windshield Washer Tank
The headlight/windshield washing systems can be kept
ready for operation down to temperatures of -20°C (-4°F) by
adding 40% alcohol.

SERVICE JOBS ON ENGINE
Tightening Cylinder Head
Remove air cleaner housing.

Unscrew cylinder head cover.
Installation: Tighten nuts and bolts in order of 1 through 9.

Max. engine temperature: 35°C (95°F).
Tighten cylinder head bolts to 78 - 82 Nm (56 to 59 ft. lbs.)
one after the other in order of 1 through 14.
Important: Never loosen cylinder head bolts;
only turn them in "tighten" direction.

Important: The cylinder head bolts are tightened by
torque angle in the 600 mile inspection.
A pertinent label must be mounted on the valve cover.
Any other type of cylinder head tightening is omitted.

Adjusting Valve Play
Turn engine with Special Tool 11 3 100.

Adjusting order = firing order (1-5-3-6-2-4) in compression
top dead center (TDC)
Adjust valve play between valve and eccentric after
loosening nut (1).
Tighten nut (1) with Special Tools 11 1 150 and 00 2 050.
Tightening torque¹).
Intake and exhaust valve play on cold engine = 0.25 mm (0.010´´).


¹) See Specifications of Group 11

Tightening Engine Nuts and Bolts
Left and right engine mounts to front axle carrier.....Nm 43-48, Ft.Lbs. 31-35
Left and right engine mounts to support bracket .....Nm 43-48, Ft.Lbs. 31-35
Left support bracket to engine (M8).....Nm 22-24, Ft.Lbs. 16-17
Right support bracket to engine (M10).....Nm 43-48, Ft.Lbs. 31-35
Thermo reactor to cylinder head.....Nm 30-33,Ft.Lbs. 22-24
Intake manifold to cylinder head.....Nm 30-33, Ft.Lbs. 22-24
Upper and lower timing case covers.....Nm 9-11, Ft.Lbs. 6.5-8
Oil pan to crankcase and timing case cover.....Nm 9-11, Ft.Lbs. 6,5-8

Checking/Correcting Drive Belt Tightness
A correctly tightened belt must give by distance (A) = 5 to 10 mm (0.197 to 0.394´´).
Tightening Alternator Belt:
Loosen alternator at tightening bar and upper mount.
Swing out alternator and tighten bolts.

Tightening Power Steering Belt:
Loosen pump at holder and press down.
Tighten mounting bolts.
Open Flank Drive Belts:
This type of drive belt should only give by 2 to 3 mm (0.080 to 0.120´´).

Checking/Correcting Tightness of Drive Belt for
Air Conditioner Compressor.

Checking Engine Vent System for Leaks
Check gasket in oil filler cap.

Check hose for crankcase breathing for tight fit or damage.

Performing SERVICE TEST
Test Program 01 Engine
Refer to operating instructions for BMW service test unit.

SERVICE JOBS ON ENGINE ELECTRICAL SYSTEM
Important: Carry out all jobs on transistor ignition
system only with engine stopped and ignition turned off. DANGER!
Checking Tightness of Wire Connections
Check wires and plugs on engine for correct routing and tight fit.
If necessary, bend wire plugs carefully with a pliers.

Checking or Replacing Spark Plugs
Unscrew spark plugs.
Clean or replace spark plugs covered with soot or oil.
Electrode gap = 0.6 + 0.1mm (0.024 + 0.004´´).
Approved spark plugs¹).
Tighetening torque¹).
Check spark plug wires and connectors for damage and tight fit.


¹) See Specifications of Group 12

SERVICE JOBS ON FUEL INJECTION SYSTEM
Checking Connections for Tightness or Leaks
Check tightness of mountings and connections on air flow
sensor, throttle housings, air collector, vibration tubes and throttle bypass valve,
tightenning if necessary.

Tighten mounting clamps and screws of fuel injector holders.
Check lines for correct routing and leaks.

Lubricating Throttle Lever with Oil
Check throttle valve for easy movement.
Lubricate bearings with oil.
Lubricate gate of throttle lever with grease.

Checking or Replacing Air Filter Cartridge
Open fasteners.
Remove air filter cartridge.
Installation: Watch installed position of the word "TOP".

SERVICE JOBS ON EXHAUST SYSTEM
Checking Exhaust System
Check exhaust system for good condition, correct routing and leaks.

Check condition and tightness of exhaust suspension.

Check heat shields for tight fit or damage.

Checking Function of Oxygen Sensor
Connect digital tester.
Adjust engine idle speed 13 00 054.
Unscrew plug nut (1).
Install CO tester 13 0 070 in exhaust line.
Connect CO tester.


13 00 054

Pull off hose (2) from collector to carbon canister.
Don´t plug opening.
Measure and note CO level value.
CO level must be between 0.2 and 0.8% by volume
CO level too low:
1.) Leak in intake system after air flow sensor.
Check intake pipes, intake neck, hoses and
connections for leaks.
2.) Leak in crankcase.
Check valve cover seal, oil pan, oil dipstick
and vent line for leaks.

Tighten CO level control screw with Special Tool 13 1 060.
This should not change the CO level.
Oxygen sensor is defective, if CO level rises.

Disconnect plug (3) for oxygen sensor.
Readjust the high CO level to the value measured
earlier with the oxygen sensor.
Connect plug (3).
Important: If car had been operated on leaded
gasoline, replace oxygen sensor and catalytic converter.

Checking Fuel Evaporation System
Check tightness of hose lines and connections on
fuel evaporation system.
Check filter plate on carbon filter for plugging,
replacing carbon filter if necessary.

Checking Fuel System for Leaks
Check tank cap and gasket, fuel tank and lines
for leaks or damage (visual inspection).

SERVICE JOBS ON COOLING SYSTEM
Tightening Hose Clamps on Cooling System
Check coolant hoses for damage and correct routing.

Tighten all hose clamps on radiator and engine.

Checking EGR System
Includes: Checking function of air pump, coasting
blowoff valve, check valve, thermo valve,
pressure converter and EGR valve, see 11 70 009.


11 70 009

From 1980 Models:
Checking Exhaust System
Check exhaust system for good condition, correct
routing and leaks.
Remove heat shields to check joints and gaskets for leaks.
Check catalytic converter for external distortion,
cracks or rattling.
Important: If car had been operated on leaded
gasoline, replace catalytic converter and oxygen sensor.

Check condition and tightness of exhaust suspension.

Check screws, nuts and bolts on heat shields and
guards for tightness.

Checking Tire Pressure Values (Including Spare Wheel)
Note temperature of tires.
Note car load condition.
Always take highest pressure for spare wheel tire.
Install dust caps.
Tire pressure values¹).


¹) See Specifications of Group 36

Inspecting Tires
Tread depth of tires must not be worn to less
than 3 mm (0.120´´) over entire tire width.
Check tires for one-sided wear.
Check tires and wheel rims for damage and correct size¹) and type.


¹) See Specifications of Group 36

Checking Tightness of Wheel Bolts
Check tightness of wheel bolts with a torque wrench.
Tightening torque¹).


¹) See Specifications of Group 36

SERVICE JOBS ON BODY
Checking Function of Locks
Check function and adjustment of locks on
doors, engine hood and trunk lid, adjusting if necessary.

Inspecting Chrome and Paint Finish
Inspect chrome parts for damage or defects.
Check body paint for scratches, dust inclusions and
silicone pockets.

SERVICE JOBS ON BODY EQUIPMENT
Checking Interior Equipment
Check headliner, trim panels and carpets for
correct installation, damage and dirt.

Checking Seat Belts
Check that seat belts function correctly, are in
good condition and anchored firmly.

SERVICE JOBS ON GENERAL ELECTRICAL SYSTEM
Checking Function of Lights
Check overnight lights, main and high beam headlights,
stop lights, backup lights, rear fog light, license plate light,
turn signals, hazard lights and horn for correct function,
condensation and damage.

Check function of heater blower, indicator lamps,
instrument lights, cigar lighter, inside lamp, glove box lamp,
trunk and engine compartment lamps.

Checking Windshield Wipers
Check function of wipe/wash intermittent action switch.
Check windshield wiper arms and rubber blades.

Check function of windshield washer system.

If stream does not hit within circle (A), the
spray jet will have to be adjusted.
A = 50mm (2´´)
B = 200mm (8´´)

Checking Tools and Documents Supplied with Car
Checking for Completeness
Check whether contents of toolbox is complete.

@@BCheck whether car has spare keys, owner´s manual,
service booklet, list of dealers and warranty cards, as
well as car jack and wheel bolt wrench.

Final Inspection
During test drive check traffic safety and function of engine, cold start device,
cooling system, transmission, final drive, steering and brakes.
After adjustment of parking brake, pull up lever by 4 teeth and drive
car about 400 m (400 yds.).
After test drive check engine, cooling system, transmission, final drive,
steering, brakes, radiator cap, fuel tank and lines for leaks.
Visually inspect function of air conditioner and flow of refrigerant at receiver/drier sight glass.

Check engine idle speed and CO level - see OO-12.

Check steering wheel straight ahead position and, if applicable,
reposition steering wheel (not for free transfer inspection).
Check steering wheel´s straight ahead position during test drive.
To reposition steering wheel remove BMW emblem, unscrew nut,
take off steering wheel and install in straight ahead position.
Replace self-locking nut.
Tightening torque¹),


¹) See Specifications of Group 32

Check clutch controls (not for free transfer inspection). Clutch pedal
must not have any mechanical play, e.g. missing bearing bushings.
After flooring the clutch pedal and waiting about 3 seconds, it should be
possible to engage reverse gear without mechanical noise.
Check brakes for one-sided pull or flattering during test drive. Watch indicator lamps.