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. | |
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). ¹) See Specifications of Groups 23 and 24 ¹) See Specifications of Groups 23 and 24 | |
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. | |
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. | |
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). 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. Improtant: Replace brake fluid annually. | |
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 | |
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. | |
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 (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. | |
Check hose for crankcase breathing for tight fit or damage. | |
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. | |
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 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. | |
b) CO Level Detach purge line (2) between carbon canister and air collector. Don´ t seal opening. | |
Unscrew plug nut (1) from connection for CO tester and screw on CO tester 13 0 070. Connect CO tester. | |
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. | |
CO level at idle speed must not change when pulling off plug for oxygen sensor. If applicabe, adjust CO level. | |
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. | |
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. | |
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. | |
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. | |
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. | |
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 32 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. 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. | |
Checking Mechanical Steering Play (pressure point adjusted) Hold steering drop arm in straight ahead position with Special Tool 32 4 040. | |
Open valve (2). Shut valve (1). Run engine having operating 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 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). | |
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 | |
SERVICE JOBS ON REAR AXLE Checking Output Shafts Check bellows of output shafts for damage and leaks. | |
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. | |
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 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. | |
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. | |
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´´). | |
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. | |
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. | |
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. | |
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). 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 | |
SERVICE JOBS ON BODY Checking Function of Locks Check function and adjustment of locks on doors, engine hood and trunk lid, adjusting if necessary. | |
Lubricating Hinges with Oil/Grease Lubricate hinges on doors, engine hood and trunk lid with oil. Apply a light coat of grease to locks. | |
Tightening Bolts and Nuts Tighten bolts and nuts of doors, engine hood and trunk lid. | |
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 = 50 mm (2´´) B = 200 mm (8´´) | |
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 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. |