indicates that the direction indicator and/or
hazard fuse has blown, check the wiring for a
short-circuit before fitting a new fuse.
4Make sure that the new unit is identical to
the original. Compare the old one to the new
one before fitting it.
5Refitting is the reverse of removal.
6 Steering column switches-
removal and refitting
1
Warning: Some later models are
equipped with an airbag or
Supplemental Restraint System
(SRS). To avoid possible damage
to this system, the manufacturer
recommends that, on airbag-equipped
models, the following procedure should be
left to a dealer service department, or
other specialist, because of the special
tools and techniques required. There is a
risk of injury if the airbag is accidentally
triggered.
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you have
the correct activation code
before disconnecting the battery, Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
1Disconnect the battery negative cable,
remove the steering wheel (see Chapter 10)
and steering column shrouds (see Chapter 11).
Direction indicator/headlight
switch
2Where necessary, remove the switch
mounting screws. Depress the tabs and pull
the switch out of the steering column
mounting (see illustration).
3Trace the switch wires down the steering
column to the electrical connector, and
unplug them (see illustration).
4Refitting is the reverse of removal.
Wiper/washer switch
5Where necessary, remove the switch
mounting screws.
6Depress the release clip, and detach the
switch from the steering column mounting
(see illustration). Trace the switch wiring
down the steering column to the electrical
connector, and unplug it.
7Refitting is the reverse of removal.
Cruise control switch
8Remove the wiper/washer switch.
9Where necessary, remove the switch
mounting screw. Squeeze the release tabs,
and withdraw the switch from the mounting
(see illustration).
10Disconnect the switch electrical
connector from the harness at the base of the
steering column.
11Refitting is the reverse of removal.
7 Ignition switch-
removal and refitting
1
Warning: Some later models are
equipped with an airbag or
Supplemental Restraint System
(SRS). To avoid possible damage
to this system, the manufacturer
recommends that, on airbag-equipped
models, the following procedure should be
left to a dealer service department, or
other specialist, because of the specialtools and techniques required. There is a
risk of injury if the airbag is accidentally
triggered.
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you have
the correct activation code
before disconnecting the battery, Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
Removal
1Disconnect the battery negative cable.
2Remove the steering wheel (see Chap-
ter 10).
3Remove the steering column shrouds (see
Chapter 11).
4Where necessary, remove the direction
indicator/headlight control switch (see Sec-
tion 6).
5Detach the clips by inserting a small
screwdriver into the openings on the sides
while pulling out on the switch (see
illustration).
6Unplug the electrical connector from the
harness at the base of the steering column,
and remove the switch.
Refitting
7Refitting is the reverse of removal.
Body electrical systems 12•3
6.3 Follow the wiring down the steering
column to the connector6.2 Squeeze the tabs to release the switch
from the mounting
6.9 Cruise control switch removal6.6 Squeeze the wiper/washer switch tabs
and pull it directly out of the mounting
12
5.1 The direction indicator/hazard warning
flasher unit is located on the steering
column on most models - squeeze the
tabs to detach it
8 Radio- removal and refitting
1
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you have
the correct activation code
before disconnecting the battery, Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
Removal
1Disconnect the battery negative cable.
2The radios on most models are held in place
by internal clips which are usually located at
the sides or corners of the unit faceplate.
Removal requires a special tool which is
inserted into the holes to release the clips so
the radio can be pulled out. These tools can be
fabricated from heavy wire, or are available
from your dealer or a car audio specialist. On
anti-theft radios, the clips are moved in and
out by internal screws which require another
type of tool. Insert the tool into the holes until
the clips release, then withdraw the radio from
the dash panel. Disconnect the wiring from the
radio and remove it.3On some models, the radio is held in place
by screws located beneath the faceplate. The
control knobs must be pulled off before the
faceplate can be withdrawn.
Refitting
4Refitting is the reverse of removal.
9 Aerial- removal and refitting
1
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you have
the correct activation code
before disconnecting the battery, Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
Removal
1Disconnect the battery negative cable.
2Use circlip pliers to unscrew the aerial
mounting nut.
3Open the boot lid/tailgate and remove the
left side trim panel. On some models, the jack
and tail light cluster cover will have to be
removed first.
4Unplug the aerial power and radio lead
connectors (as applicable), remove the
retaining bolts, and remove the aerial and
motor assembly.
Refitting
5Refitting is the reverse of removal.
10 Instrument cluster-
removal and refitting
2
Caution: The instrument cluster
and components are very
susceptible to damage from
static electricity. Make sure you
are earthed and have dischargedany static electricity (by touching an object
such as a metal water pipe) before
touching the cluster or components.
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you have
the correct activation code
before disconnecting the battery, Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
Removal
1Disconnect the battery negative cable.
2As necessary, remove the steering column
shrouds and lower trim panel (see Chap-
ter 11).
3Remove the screws holding the cluster to
the facia (see illustration). Note the location
of the lower screws to ensure they are refitted
in the same place. On 3-Series models, the
length of the two lower inner screws must not
exceed 9.5 mm.
4Tilt the top of the cluster back, reach
behind it and detach the electrical connectors
by pressing on the levers, then lift the cluster
out of the facia opening (see illustration).
5For access to the cluster components,
release the catches or remove the screws,
and separate the two halves (see
illustration).
Refitting
6Refitting is the reverse of removal.
11 Service Indicator (SI) board-
general information
All models that have service indicator lights
are equipped with a Service Indicator (SI)
board located in the instrument cluster. This
board turns the lights on at the proper mileage
intervals. The lights can only be turned off
using a special tool which plugs into the
engine check connector (see Chapter 1). The
12•4 Body electrical systems
10.5 Turn the plastic knobs to release the
back of the cluster (some models use
screws)10.4 Push on the levers to detach the
cluster electrical connectors10.3 Use a Phillips screwdriver to remove
the instrument cluster retaining screws
7.5 Insert a screwdriver into the openings
(arrowed) on each side of the switch to
release the clip while pulling out
13 Headlights- adjustment
2
Note:The headlights must be aimed correctly.
If adjusted incorrectly, they could momentarily
blind the driver of an oncoming vehicle and
cause a serious accident, or seriously reduce
your ability to see the road. The headlights
should be checked for proper aim every
12 months (as is done during the MOT test),
and any time a new headlight is fitted or front-
end body work is performed. It should be
emphasised that the following procedure will
only provide a temporary setting until the
headlights can be adjusted by a properly-
equipped garage.
1Each headlight has two adjusting screws,
one controlling up-and-down movement and
one controlling left-and-right movement (see
illustration). It may be necessary to remove
the grille (see Chapter 11) for access to these
screws.
2There are several methods of adjusting the
headlights. The simplest method requires a
blank wall (or garage door) 25 feet in front of
the vehicle, and a level floor.
3Position masking tape vertically on the wall,
to mark the vehicle centreline and the
centreline of both headlights. Note:It may be
easier to position the tape on the wall with the
vehicle parked only a few inches away, and
then move the vehicle back the required
distance when all marks have been made.
4Make a horizontal line on the wall to mark
the centreline of all headlights.
5Move the vehicle back so that it is 25 feet
away from the marked wall (keep the front end
of the vehicle square to the wall). Adjustment
should be made with the vehicle sitting level,
the fuel tank half-full, and with no unusually
heavy loads in the vehicle.
6Switch on the dipped beam. The bright
spots on the wall should be two inches below
the horizontal line, and two inches to the left
of the headlight vertical lines. Adjustment is
made by turning the adjusting screw to raise
or lower the beam. The other adjusting screwshould be used in the same manner to move
the beam left or right.
7With main beam on, the bright spots on the
wall should be exactly on the vertical lines,
and just below the horizontal line. Note:It may
not be possible to position the headlight aim
exactly for both main and dipped beams. If a
compromise must be made, keep in mind that
the dipped beam is most used, and will have
the greatest effect on driver safety.
8Have the headlights adjusted by a dealer
service department or qualified garage at the
earliest opportunity.
14 Headlight housing-
removal and refitting
1
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you have
the correct activation code
before disconnecting the battery, Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
Removal
1Disconnect the battery negative cable.2Remove the side grille (see Chapter 11),
then remove the rear cover(s) where
necessary.
3Unplug the headlight (sealed beam-type) or
remove the bulb (halogen bulb-type).
4Remove the screws and detach the housing
(see illustration).
Refitting
5Refitting is the reverse of removal.
15 Bulb renewal
1
1The lenses of many lights are held in place
by screws, which makes it a simple procedure
to gain access to the bulbs.
2On some lights, the lenses are held in place
by clips. The lenses can be removed by using
a small screwdriver to prise them off.
3Several bulbs are mounted in self-earthing
holders, and are removed by pushing in and
turning them anti-clockwise (see illustration).
The bulbs can then be removed (see
illustrations).
4The tail lights on 3-Series models are
accessible after removing the housing, then
removing the bulbs (see illustrations).
5To gain access to the facia lights, the
instrument cluster will have to be removed
first (see illustration).
12•6 Body electrical systems
15.3c . . . then pull the bulb from the
holder15.3b On models with high-mounted
centre brake lights, the self-earthing
holder is accessible from the luggage area
- pull the holder out . . .15.3a The tail light bulbs on later 5-Series
models are in self-earthing holders which
can be simply pulled out of the housing -
the bulb is then removed from the holder
14.4 Remove the screws (arrowed) and
detach the headlight housing13.1 The headlight adjustment screws
(arrowed) are accessible from the back of
the headlight on 3-Series models
16 Windscreen/tailgate wiper
motor- removal and refitting
2
Caution: If the radio in your
vehicle is equipped with an anti-
theft system, make sure you have
the correct activation code
before disconnecting the battery, Refer to
the information on page 0-7 at the front of
this manual before detaching the cable.
Note: If, after connecting the battery, the
wrong language appears on the instrument
panel display, refer to page 0-7 for the
language resetting procedure.
1Disconnect the battery negative cable.
Windscreen wiper motor
2Remove the covers and nuts, then detach
the wiper arms (see illustrations).
3Prise out the retaining clips and detach the
cowl grille for access to the wiper assembly.
4Remove the screws or nuts and detach the
wiper cover located on the engine
compartment bulkhead.
5Unplug the electrical connector and detach
the wiper linkage.
6Mark the relationship of the wiper shaft to the
linkage. Detach the wiper link from the motor
shaft by prising carefully with a screwdriver.
7Remove the three retaining bolts and
remove the wiper motor from the vehicle.
8Refitting is the reverse of removal. When
fitting the motor, if necessary plug in theconnector and run the motor briefly until it is
in the “neutral” (wipers parked) position.Tailgate wiper motor
9On 3-Series models, remove the cover and
nut, then detach the wiper arm (see
illustration). On 5-Series models, open the
rear window away from the tailgate.
10As applicable, remove the trim panel(s),
then disconnect the washer tube and the
wiring plug.
11Unscrew the mounting nuts and withdraw
the wiper motor (see illustrations). On 5-
Series models, the wiper blade and pivot
mechanism may be removed from the rear
window if necessary after removing the trim
panels (see illustration).
Body electrical systems 12•7
15.5 After removing the instrument cluster
(see Section 10), turn the bulbholder anti-
clockwise to remove the bulb15.4b . . . then remove the bulb from the
housing15.4a On 3-Series models, the entire tail
light housing assembly is self-earthing
through the mounting screw - loosen the
plastic screw and pull the housing back . . .
16.11a Removing the tailgate wiper motor (3-Series)
16.2b After removing the nut, use a magnet to lift out the metal
washer16.2a Use a small screwdriver to detach the wiper arm nut cover,
or swivel the cover up
16.9 Removing the tailgate wiper arm nut (3-Series)
12
REF•9
REF
Fault Finding
Engine
m mEngine will not rotate when attempting to start
m mEngine rotates, but will not start
m mEngine hard to start when cold
m mEngine hard to start when hot
m mStarter motor noisy or excessively-rough in engagement
m mEngine starts, but stops immediately
m mOil puddle under engine
m mEngine idles erratically
m mEngine misses at idle speed
m mEngine misses throughout driving speed range
m mEngine misfires on acceleration
m mEngine surges while holding accelerator steady
m mEngine stalls
m mEngine lacks power
m mEngine backfires
m mPinking or knocking engine sounds when accelerating
or driving uphill
m mEngine runs with oil pressure light on
m mEngine runs-on after switching off
Engine electrical system
m
mBattery will not hold charge
m mIgnition (no-charge) warning light fails to go out
m mIgnition (no-charge) warning light fails to come on
when key is turned
Fuel system
m mExcessive fuel consumption
m mFuel leakage and/or fuel odour
Cooling system
m
mOverheating
m mOvercooling
m mExternal coolant leakage
m mInternal coolant leakage
m mCoolant loss
m mPoor coolant circulation
Clutch
m
mPedal travels to floor - no pressure or very little resistance
m mFluid in area of master cylinder dust cover and on pedal
m mFluid on slave cylinder
m mPedal feels “spongy” when depressed
m mUnable to select gears
m mClutch slips (engine speed increases with no increase in
vehicle speed)
m mGrabbing (chattering) as clutch is engaged
m mNoise in clutch area
m mClutch pedal stays on floor
m mHigh pedal effort
Manual transmission
m
mVibration
m mNoisy in neutral with engine running
m mNoisy in one particular gear
m mNoisy in all gears
m mSlips out of gear
m mLeaks lubricant
Automatic transmission
m
mFluid leakage
m mTransmission fluid brown, or has a burned smell
m mGeneral shift mechanism problems
m mTransmission will not kickdown with accelerator pedal
pressed to the floor
m mEngine will start in gears other than Park or Neutral
m mTransmission slips, shifts roughly, is noisy, or has no drive
in forward or reverse gears
Brakes
m mVehicle pulls to one side during braking
m mNoise (high-pitched squeal) when the brakes are applied
m mBrake vibration (pedal pulsates)
m mExcessive pedal effort required to stop vehicle
m mExcessive brake pedal travel
m mDragging brakes
m mGrabbing or uneven braking action
m mBrake pedal feels “spongy” when depressed
m mBrake pedal travels to the floor with little resistance
m mHandbrake does not hold
Suspension and steering
m
mVehicle pulls to one side
m mAbnormal or excessive tyre wear
m mWheel makes a “thumping” noise
m mShimmy, shake or vibration
m mHigh steering effort
m mPoor steering self-centring
m mAbnormal noise at the front end
m mWandering or poor steering stability
m mErratic steering when braking
m mExcessive pitching and/or rolling around corners or
during braking
m mSuspension bottoms
m mUnevenly-worn tyres
m mExcessive tyre wear on outside edge
m mExcessive tyre wear on inside edge
m mTyre tread worn in one place
m mExcessive play or looseness in steering system
m mRattling or clicking noise in steering gear