Changing Engine Oil and Replacing Oil Filter
Engine at operating temperature.
Unscrew filler cap.
Unscrew oil drain plug from oil pan.
Installation: Check oil drain plug and seal, replacing if necessary.
Tightening torque¹).


¹) See Specifications of Group 11

Unscrew oil filter housing.
Clean oil filter housing.
Replace oil filter cartridge.
Installation: Check seals, replacing if necessary.
Tightening torque¹).


¹) See Specifications of Group 11

Add 5.0 ltr. (10.5 pints) of brand name oil plus
0.75 ltr. (1.5 pints) for oil filter.
Run engine and recheck oil level.
Refer to Service Information of Group 11 for approved oils.

Changing Manual Transmission Oil
Transmission at operating temperature.
Unscrew filler plug and oil drain plug.
Clean drain plug, check and install again.
Add transmisson oil.
Refer to Service Information of Group 23 for approved oils.
Installation: Tightening torque¹).


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

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.

Changing Final Drive Oil
Final drive at operating temperature.
Unscrew oil filler and drain plugs.
Clean drain plug, check seal and reinstall.
Installation: Oil volume and tightening torque¹).
Add oil to raise level to lower edge of filler opening.
Refer to Service Information of Group 33 for approved oils.


¹) See Specifications of Group 33

Checking/Correcting 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.

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.

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 pertinemt 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 443-48, 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).....Nm22-24, 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 Stearing Belt:
Loosen pump at holder and press down.
Tighten mounting bolts.
Open Flank Drive Belts:
This type of drive balt should only give by 2 to 3 mm (0.080 to 0.120´´).

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

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

SERVICE JOBS 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, tightening 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.

Adjusting Engine Idle Speed and CO Level
Requires engine at operating temperature, i.e. min. oil
temperature 60°C (140°F), correct ignition timing and valve play,
perfect condition air filter cartridge and alibrated, warm CO tester.
a) Engine Idle Speed
Detach hose from collector to carbon filter and
do not plug openings.
Detach air hose from air pump and insert plug.

Adjust idle speed to 950 ± 100 rpm with screw (1).
Turning screw (1) clockwise lowers idle speed.
Engine must run as smooth as possible for adjusting.

b) CO Level
For CO level adjustments, note plug (3) on
L-Jetronic control unit for high altitude correction.
If car is operating in a high altitude area, plug (3)
must be connected.

CO level at idle speed must be between 1.5 and 3.0% by volume.

CO level at idle speed: 1.5 to 3.0% by volume.
CO level too low:
a) Leak in intake system after air flow sensor.
b) Auxiliary air valve defective 11 61 090.
c) Fuel pressure regulator defective 13 51 200.
d) Fuel filter partially displaced 13 32 051.
e) Check fuel pump pressure 13 31 029.
f) EGR valve leaks 11 71 501.
g) Exchange control unit for testing 13 61 000.
h) Check function of fuel injection electric equipment
with tester, Bosch 0684 100 202 - 13 60 009.
Positions a) ... h) not cause:
Remove end cap (3) with an angled scribe or similar
tool. Correct CO level to specifications with idle air
screw in air flow sensor, using Special Tool 13 1 060.
CO level too high:
a) Oil dipstick not tight enough in guide tube.
b) Too much oil in crankcase.
c) Intake and exhaust valves leak.
d) Exchange air flow sensor for testing 13 62 000.
e) Cold starting device won´t turn off 13 64 009.
f) Check function of fuel injection electric equipment with
tester, Bosch 0684 100 202 - 13 60 009.
g) Fuel injectors leak 13 64 501.
Positions a) ... g) not cause:
Remove end cap (3) with an angled scribe or similar
tool. Correct CO level to specifications with idle air
screw in air flow sensor, using Special Tool 13 1 060.


11 61 090
13 51 200
13 32 051
13 31 029

SERVICE JOBS ON FUEL TANK AND LINES
Cleaning Initial Fuel Filter in Suction Pipe
Remove cover from trunk floor.
Detach hoses (2 and 3).
(2) to fuel pump
(3) return line
Pull off plug (4).
br/ge = brown/yellow
br = brown
br/sw = bronw/black

Loosen screws.
Old Version:
Turn fuel transmitter/suction tube anticlockwise
with two crossed screwdrivers.

Clean fuel filter screen.
Installation: Check gasket and round cord seal
(19), replacing if necessary.
Only when Replacing Fuel Transmitter:
Remove transport guard (20).

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

SERVICE JOBS ON PROPELLER SHAFT
Checking Propeller Shaft for Wear
Check rubber coupling for wear and distortion
(visual inspection).

Check center bearing for cracks (visual inspection).

Check whether universal joints have play.

Tightening Bolts and Nuts
Propeller shaft to manual transmission ...Nm 68-76, Ft.Lbs. 49-55
Important: Only turn nuts.
Propeller shaft to automatic transmission.....Nm 43-48, Ft.Lbs. 31-35
Center bearing to body.....Nm 22-24, Ft.Lbs. 16-17
Propeller shaft to final drive.....Nm 68-76, Ft.Lbs. 49-55

SERVICE JOBS ON FRONT AXLE
Checking/Adjusting Front Wheel Bearing Play
Remove and install grease cap with Special Tool 31 2 000.
Remove cotter pin and unscrew castle nut.
If necessary, replace grease packing.

Tighten castle nut to 30-33 Nm (22-24 ft. lbs) while
turning wheel hub continuously.
This will settle tapered pins and bearing inner
races. Grease causing play will also be forced out.
Turn tightened bearing assembly at least 2 more turns.
In so doing, do not loosen or tighten castle nut any further.

Loosen castle nut until there is axial bearing play,
the hut being turned again.
Tighten castle nut by max. 3 Nm (2 ft. lbs), then
turn back to nearest hole and lock with cotter pin.
Checking Axial Bearing Play:
Tabbed disc (1) must move without noticeable resistance.

Tightening Bolts and Nuts
Support bearing to wheel house.....Nm 22-24, Ft.Lbs. 16-17
Front axle carrier to engine carrier.....Nm 43-48, Ft.Lbs. 31-35
Control arm to front axle carrier.....Nm 81-90, Ft.Lbs. 59-65
Stabilizer to control arm.....Nm 70-90, Ft.Lbs. 51-65
Bracket for stabilizer.....Nm 47-52, Ft.Lbs. 34-38

Checking Steering Gear Adjustment
Important: The steering gear must be in good general
condition before a pressure point adjustment can be made.
Position front wheels to point straight ahead.
Remove cotter pin and unscrew castle nut.
Installation: Tightening torque¹).
Lock castle nut with a cotter pin.


¹) See Specifications of Group 32

Press off center tie rod from steering drop arm
with Special Tool 332 2 070.

Take off BMW emblem.
Find straight ahead position by taking half of
total number of steering wheel turns.
Turn steering wheel anticlockwise by about
1 turn.
With Special Tool 00 2 000 mounted, turn
clockwise past straight ahead position and
take frictional torque reading.

To adjust, turn steering wheel anticlockwise from
straight ahead position by about 1 turn.
Inportant: In this position the worm cannot be
pressed one-sided in its bearing by the steering sector
shaft, which would erroneously show lack of play.
Loosen locknut (1).
Turn adjusting screw (2) until the frictional torque
increases by 30 to 40 Ncm (2.6 to 3.5 in. lbs.) when
passing straight ahead positon.

Checking Mechanical Steering Play (pressure point adjusted)
@NHold steering drop arm in straight ahead position
with Special Tool 32 4 040.

Open valve (2).
Shut valve (1).
Run engine having operation temperature at idle speed.
Open valve (1).
Read flow-through pressure.

Paste strips of paper on steering wheel hub and
casing upper section.
Turn steering wheel anticlockwise carefully until
pressure gage shows 1 bar (14 psi) more than the
flow-through pressure.
Mark position of steering wheel hub at (A).
Turn steering wheel colckwise carefully until
pressure gage 32 4 000 shows 1 bar (14 psi) more
than flow-through pressure.
Again mark position of steering wheel hub on (A).

Total travel (B) must not exceed 7 mm (0.275´´).
Check joint coupling, if 7 mm (0.275´´) are exceeded.
Replace steering gear, if joint coupling is not cause.
Remove pressure gage 32 4 000.
Fill and bleed hydraulic system 32 13 006.


32 13 006

Tightening Bolts and Nuts of Steering
Power steering pump to engine.....Nm 22-24, Ft.Lbs. 16-17
Steering gear to front axle carrier.....Nm 43-48, Ft.Lbs. 31-35
Joint coupling to joint flange.....Nm 20-23, Ft.Lbs. 15-17
Joint flange to steering gear and steering spindle.....Nm 25-28, Ft.Lbs. 18-20
Tie rod bolts.....Nm 12-15, Ft.Lbs. 9-11
Tie rod castle nuts.....Nm 35-40, Ft.Lbs. 25-29
Tie rod arm to steering knuckle.....Nm 45-60, Ft.Lbs. 33-43

Checking Toe
Requirements for checking wheel alignment:
1. Good, uniform tire treads.
2. Specified tire pressures.
3. Perfect condition wheel rims.
4. Specified wheel bearing play.
5. Car in normal position: 2 x 68 kg (2 x 150 lbs.) on
front seats, 1 x 68 kg (150 lbs.) on rear seats,
21 kg (46 lbs.) in trunk and full fuel tank.
Check toe¹) with optical aligner, correcting if necessary.


¹) See Specifications of Group 32

Tightening Bolts and Nuts
Cover to final drive case.....Nm 20-25, Ft.Lbs. 15-18
Vent cover.....Nm 9-10, Ft.Lbs. 6.5-7.0
Rear axle carrier to body follr plate.....Nm 140-155, Ft.Lbs. 101-112
Rubber mount to rear axle carrier.....Nm 36-40, Ft.Lbs. 26-29
Strut to body floor plate.....Nm 22-24, Ft.Lbs. 16-17
Final drive to rrear axle carrier.....Nm 72-80, Ft.Lbs. 52-58
Final drive to rubber mount.....Nm 72-80, Ft.Lbs. 52-58
Rubber mount to body.....Nm 43-48, Ft.Lbs. 31-35
Trailing arm to axle carrier (pulled in with car in normal positon).....Nm67-75, Ft.Lbs. 49-54
Output shafts to drive lange and final drive.....Nm 33-36, Ft.Lbs. 24-26
Spring strut absorber to wheel house.....Nm 25-28, Ft.Lbs. 18-20
Spring strut absorber to trailing arm (pulled in with car in normal pos.).....Nm 120-130, Ft.Lbs. 87-94

SERVICE JOBS ON BRAKE SYSTEM
Checking Connections and Lines
Check brake hoses for damage and tears.

Check lines for correct routing, damage and corrosion.

Check parking brake cables for damage, easy
movement and correct routing.

Checking Brake System for Leaks
1. Visual inspection.
2. Load brake pedal. If brake pedal drops slowly,
check connections, brake master cylinder, wheel
brake cylinders and brake calipers.

Checking Parking Brake Adjustment
@NPull up parking lever by 4 teeth.
It must still be just barely possible to turn the wheels by hand.

Adjusting Parking Brake:
Pull off rubber cap.

Unscrew nuts for parking brake cables enough
that cables are slack.

Unscrew and remove a wheel bolt from each
rear wheel. Turn wheel that tapped bore is past
the perpendicular by 10° in clockwise direction.
Turn adjusting nut with a screwdriver to move
out the parking brake shoes so that the brake
disc can no longer turn. Then loosen the adjusting
nut by 4 to 6 threads.
Adjusting nut up = tighten.
Adjusting nut down = loosen.
Brake discs must turn freely.

Important: If adjusting nuts are hard to turn,
take off rear wheel 36 10 300 and, if necessary,
rear brake discs 34 21 300.


36 10 300
34 21 300

Pull up parking brake lever by five teath, starting
from fully released position.
Tighten adjusting nut (2) until wheel is stopped.
Tighten locknut (1).
Finally check whether both rear wheels turn easily,
when parking brake lever is released.
Pull up parking brake lever slightly and turn rear
wheels by hand to check, whether adjustment of
both cables is uniform.

Tightening Bolts and Nuts
Front caliper to steering knuckle.....Nm 80-95, Ft.Lbs. 58-69 L
Rear caliper to trailing arm.....Nm 60-67, Ft.Lbs. 43-48

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

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 looks on
doors, engine hood and trunk lid, adjusting if necessary.

SERVICE JOBS ON GENERAL ELECTRICAL SYSTEM
Checking Function of Lights
Check overnight lights, main and hight 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 fo heater blower, indicator lamps,
instrument lights, cigar lighter, inside lamp, glove box lamp,
trunk and engine compartment lamps.

Checking and Aiming Headlight Beams
Requirements: Correct tire pressures. Car on
level surface. Center of rear seat loaded by a
weight or person weighing 70 kg (155 lbs.).
Check beams of low and high beam headlights
with an optical aimer.
Take off covers and correct beams with adjusting screws.
(1) Vertical control
(2) Lateral control

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 00-12.

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 repositon 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.