BMW 3- & 5-Series Service and Repair Manual - e34.hu

1 BMW 3- & 5-SeriesService and Repair ManualA K Legg LAE MIMI and Larry WarrenModels 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 SeriesAll rights reserved.

2 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 85960 236 3 British Library Cataloguing in Publication DataA catalogue record for this book is available from the British by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,Somerset BA22 7JJ, EnglandHaynes PublishingSparkford, Nr Yeovil, Somerset BA22 7JJ, EnglandHaynes North America, Inc861 Lawrence Drive, Newbury Park, California 91320, USAE ditions Haynes , rue Saint Honor , 75001 PARIS, FranceHaynes Publishing Nordiska ABBox 1504, 751 45 Uppsala, Sweden(1948-256-11AA3)ABCDEFGHIJKLMNOPQR ST1 2 3 LIVING WITH YOUR BMWI ntroductionPage 0 4 Safety First!

3 Page 0 6 Anti-theft audio systemPage0 7 Instrument panel language displayPage0 7 Roadside RepairsJacking, towing and wheel changing Page0 8 Jump startingPage0 9 Identifying leaksPage0 10 ROUTINE MAINTENANCER outine Maintenance and ServicingPage1 1 Lubricants and fluidsPage1 3 Maintenance schedulePage1 4 Weekly checksPage1 7 Every 6000 milesPage1 11 Every 12 000 milesPage1 16 Every 24 000 milesPage1 23 Every 60 000 milesPage1 26 ContentsREPAIRS & OVERHAULE ngine and Associated SystemsIn-car engine Repair procedures Page 2A 1 General engine overhaul proceduresPage2B 1 Cooling, heating and air conditioning systemsPage3 1 Fuel and exhaust systems Page 4 1 Engine electrical systems Page5 1 Engine management and emission control systemsPage6 1 TransmissionManual transmissionPage7A 1 Automatic transmission Page7B 1 Clutch and driveline Page 8 1 Brakes Braking systemPage 9 1 Suspension Suspension and steering systemsPage 10 1 Body Equipment Bodywork and fittings Page 11 1 ElectricalBody electrical systemsPage 12 1 Wiring DiagramsPage 12 10 REFERENCEMOT Test ChecksChecks carried out from the driver s seatPageREF 1 Checks carried out with the vehicle on the

4 GroundPageREF 2 Checks carried out with the vehicle raisedPageREF 3 Checks carried out on your vehicle s exhaust emission systemPageREF 4 Tools and Working FacilitiesPage REF 5 General Repair ProceduresPage REF 8 Fault FindingPage REF 9 Conversion factorsPageREF 17 Automotive chemicals and lubricantsPageREF 18 Buying spare parts and vehicle identification numbersPageREF 19 Glossary of Technical TermsPageREF 20 IndexPage REF 25 Contents0 4 IntroductionThe 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.

5 Convertibleand Touring (Estate) models were introducedfor 1988, and these models have continued inE30 form to 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 old-shape , 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.

6 Transmissions are a five-speedmanual, or three- or four-speed transmission is mounted to the back ofthe engine, and power is transmitted to thefully-independent rear axle through a two-piece propeller shaft. The final drive unit isbolted solidly to a frame crossmember, anddrives the rear wheels through driveshaftsequipped with inner and outer constantvelocity 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 spring-over-shock absorber struts, or coil springsand conventional shock absorbers,depending on brakes are disc type at the front, witheither drums or discs at the rear, dependingon model.

7 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).

8 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 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.

9 No liability can be acceptedby the authors or publishers for loss,damage or injury caused by any errors in, or omissions from, theinformation vehiclesThe main project vehicle used in thepreparation of this Manual for the UK marketwas a 1988 BMW 318i with an M40 to the BMW 3- and 5-SeriesBMW 320i Saloon (E30)0 5 IntroductionBMW 518i (E28)BMW 325i Touring (E30)BMW 535i (E34)BMW 325i Convertible (E30)0 6 Safety First!Working on your car can be page shows just some of the potentialrisks and hazards, with the aim of creating asafety-conscious hazardsScalding Don t remove the radiator or expansiontank cap while the engine is hot.

10 Engine oil, automatic transmission fluid orpower steering fluid may also be dangerouslyhot if the engine has recently been Beware of burns from the exhaust systemand from any part of the engine. Brake discsand drums can also be extremely hotimmediately after When working under or neara raised vehicle,alwayssupplement thejack with axlestands, or a car whichis only supported by a jack. Take care if loosening or tightening high-torque nuts when the vehicle is on loosening and final tightening shouldbe done with the wheels on the Fuel is highly flammable; fuel vapour isexplosive.