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).


Siehe auch ¹) See Specifications of Group 11
73000040 - click to zoom
 
Unscrew oil filter housing.
Clean oil filter housing.
Replace oil filter cartridge.
Installation: Check seals, replacing if necessary.
Tightening torque¹).


Siehe auch ¹) See Specifications of Group 11
73000070 - click to zoom
 
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.

73000015 - click to zoom
 
Checking/Correcting Manual Transmission Oil Level
Unscrew oil filler plug.
Add oil to raise level to lower edge of filler opening.
Refer to Service Information of Group 23 for approved oils.
Installation: Check filler plug, replacing if necessary.
Tightening torque¹).


Siehe auch ¹) See Specifications of Groups 23 and 24
Siehe auch ¹) See Specifications of Groups 23 and 24
73000026 - click to zoom
 
Checking/Correcting Automatic Transmission Oil Level
Requirements: 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.

63024017 - click to zoom
 
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.

52500016 - click to zoom
 
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).


Siehe auch ¹) See Specifications of Group 33
52500028 - click to zoom
 
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.
Improtant: Replace brake fluid annually.

52500022 - click to zoom
 
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 form battery poles on clothing.
Never work with an open flame near batteries.
Danger of expolsion

73000021 - click to zoom
 
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.

52500011 - click to zoom
 
Adjusting Valve Play
Turn engine with Special Tool 11 3 100.

63011339 - click to zoom
 
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´´).


Siehe auch ¹) See Specifications of Group 11
63011223 - click to zoom
 
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 (M 8)......22-24, Ft.Lbs. 16-17
Right support bracket to engine ( M 10).....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 Engine Vent System for Leaks
Check gasket in oil filler cap.

73300024 - click to zoom
 
Check hose for crankcase breathing for tight
fit or damage.

53000012 - click to zoom
 
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, tightening
if necessary.

73300025 - click to zoom
 
Tighten mounting clamps and screws of fuel
injector holders.
Check lines for correct routing and leaks.

73000048 - click to zoom
 
Lubricating Throttle Lever with Oil
Check throttle valve for easy movement.
Lubricate bearings with oil.
Lubricate gate of throttle lever with grease.

73000047 - click to zoom
 
Adjusting Engine Idle Speed and CO level
From 1980 Models:
a) Engine Idle Speed
Connect BMW digital tester.
Adjust idle speed to 900 ± 50 rpm with adjusting
screw (1) at throttle valve.
Turning clockwise reduces idle speed.
Engine should run sa smooth as possible.

53013041 - click to zoom
 
b) CO Level
Detach purge line (2) between carbon canister
and air collector.
Don´ t seal opening.

53011149 - click to zoom
 
Unscrew plug nut (1) from connection for CO
tester and screw on CO tester 13 0 070.
Connect CO tester.

53011148 - click to zoom
 
CO level at idle speed 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 crankcace.
Check valve cover seal, oil pan, oil dipstick
and vent line for leaks.

73034121 - click to zoom
 
CO level at idle speed must not change when
pulling off plug for oxygen sensor.
If applicabe, adjust CO level.

53011152 - click to zoom
 
Adjusting CO Level:
Important: As from 1981 models the CO level
may only be adjusted in conjunction with repairs.
Remove cap (3) with an angled scribe or similar
tool. Pull off oxygen sensor plug.
Adjust CO level to the value measured with the
oxygen sensor connected by applying Special
Tool 13 1 060 on the air control screw in the
air flow sensor.
Important: Don´t run engine at idle speed too
long - danger of overheating. If necessary, set up
ventilator in front of car.

53011150 - click to zoom
 
Checking Fuel System for Leaks
Check tank cap and gasket, fuel tank and lines
for leaks or damage (visual inspection).

63000019 - click to zoom
 
SERVICE JOBS ON COOLING SYSTEM
Tightening Hose Clamps on Cooling System
Check coolant hoses for damage and correct routing.

53000017 - click to zoom
 
Tighten all hose clamps on radiator and engine.

53000018 - click to zoom
 
SERVICE JOBS ON EXHAUST SYSTEM
Checking Exhaust System
Check exhaust system for good condition, correct
routing and leaks.

53000019 - click to zoom
 
Check condition and tightness of exhaust suspension.

53000020 - click to zoom
 
Check heat shields for tight fit or damage.

53000021 - click to zoom
 
SERVICE JOBS ON PROPELLER SHAFT
Checking Propeller Shaft for Wear
Check rubber coupling for wear and distortion
(visual inspection).

53000023 - click to zoom
 
Check center bearing for cracks (visual inspection).

53000024 - click to zoom
 
Check whether universal joints have play.

53000025 - click to zoom
 
SERVICE JOBS ON FRONT AXLE
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

 
SERVICE JOBS ON STEERING
Checking Condition of Front Axle Joints
Check condition and play of front axle joints.
Check bellows and covers.
Check joint coupling.

53000026 - click to zoom
 
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.


Siehe auch ¹) See Specifications of Group 32
52532087 - click to zoom
 
Press off center tie rod from steering drop arm
with Special Tool 32 2 070.

63032016 - click to zoom
 
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.

63300011 - click to zoom
 
To adjust, turn steering wheel anticlockwise from
straight ahead position by about 1 turn.
Important: 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 position.

63032018 - click to zoom
 
Checking Mechanical Steering Play
(pressure point adjusted)
Hold steering drop arm in straight ahead position
with Special Tool 32 4 040.

52500045 - click to zoom
 
Open valve (2).
Shut valve (1).
Run engine having operating temperature at idle speed.
Open valve (1).
Read flow-through pressure.

53000029 - click to zoom
 
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 clockwise 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).

52500047 - click to zoom
 
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.


Siehe auch 32 13 006
52500066 - click to zoom
 
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

 
SERVICE JOBS ON REAR AXLE
Checking Output Shafts
Check bellows of output shafts for damage and leaks.

52500049 - click to zoom
 
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 floor 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 rear 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 position).....Nm 67-75, Ft.Lbs. 49-54
Output shafts to drive flange 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.

53000022 - click to zoom
 
Check lines for correct routing, damage and corrosion.

53000030 - click to zoom
 
Check parking brake cables for damage, easy
movement and correct routing.

53000031 - click to zoom
 
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.

32000050 - click to zoom
 
Checking Brake Pads/Liners
1. Front and Rear Disc Brakes:
Remove wheels. Take off brake pads. Replace
brake pads worn to minimum thickness of 2.0 mm
(0.080´´) for pad without plate, or when "brake"
lamp of check control comes on.
Check surface condition of brake discs (visual
inspection).
Clean brake calipers.
Check covers.
Important: Draw off brake pad abrasion,
being careful not to inhale it.

53000064 - click to zoom
 
2. Parking Brake Liners:
Remove and install rear wheel 36 10 320.
Take off brake caliper, brake line remaining
connected.
Unscrew socket head bolt with a 4 mm wrench.
Remove brake disc from axle shaft.
Installation: Watch position of brake disc/axle
shaft flange holes. Large hole of brake disc must
align with large hole in axle shaft flange.

73000066 - click to zoom
 
Check minimum thickness and condition of brake liners.
Brake liners must not be lass than 1.5 mm (0.060´´)
at their thinnest point.
Replace brake shoes, when liners reach 1.5 mm (0.060´´).

73000037 - click to zoom
 
Checking Parking Brake Adjustment
Pull up parking brake lever by 4 teeth.
It must sitll be just barely possible to turn the
wheels by hand.

52500051 - click to zoom
 
Adjusting Parking Brake:
Pull off rubber cap.

52500057 - click to zoom
 
Unscrew nuts for parking brake cables enough
that cables are slack.

52500058 - click to zoom
 
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.

63034140 - click to zoom
 
Important: If adjusting nuts are hard to turn,
take off rear wheels 36 10 300 and, if necessary,
rear brake discs 34 21 300.


Siehe auch 36 10 300
Siehe auch 34 21 300
73034108 - click to zoom
 
Pull up parking brake lever by five teeth, starting
from fully released position.
Tighten adjusting nut (2) until wheel ist 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.

52000073 - click to zoom
 
Tightening Bolts and Nuts
Front caliper to steering knuckle.....Nm 80-95, Ft.Lbs. 58-69
Rear caliper to treiling 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).


Siehe auch ¹) See Specifications of Group 36
63300012 - click to zoom
 
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.


Siehe auch ¹) See Specifications of Group 36
63300013 - click to zoom
 
SERVICE JOBS ON BODY
Checking Function of Locks
Check function and adjustment of locks on
doors, engine hood and trunk lid, adjusting if necessary.

63041011 - click to zoom
 
Lubricating Hinges with Oil/Grease
Lubricate hinges on doors, engine hood and trunk
lid with oil.
Apply a light coat of grease to locks.

63300016 - click to zoom
 
Tightening Bolts and Nuts
Tighten bolts and nuts of doors, engine hood and
trunk lid.

63300017 - click to zoom
 
Checking Seat Belts
Check that seat belts function correctly, are in
good condition and anchored firmly.

63300020 - click to zoom
 
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.

63300021 - click to zoom
 
Check function of heater blower, indicator lamps,
instrument lights, cigar lighter, inside lamp, glove
box lamp, trunk and engine compartment lamps.

63300022 - click to zoom
 
Checking Windshield Wipers
Check function of wipe/wash intermittent action
switch.
Check windshield wiper arms and rubber blades.

53000039 - click to zoom
 
Check function of windshield washer system.

63300023 - click to zoom
 
If stream does not hit within circle (A), the
spray jet will have to be adjusted.
A = 50 mm (2´´)
B = 200 mm (8´´)

63000032 - click to zoom
 
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.

73034121 - click to zoom
 
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).


Siehe auch ¹) See Specifications of Group 32
63000021 - click to zoom
 
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.

73000096 - click to zoom