1989 BMW 5 SERIES clutch

REF•11
REF
Fault Finding
Engine misses at idle speed
m mSpark plugs worn or incorrectly-gapped (Chapter 1).
m mFaulty spark plug HT leads (Chapter 1).
m mVacuum leaks (Chapter 1).
m mIncorrect ignition timing (Chapter 5).
m mUneven or low compression (Chapter 2).
m mFaulty charcoal canister, where fitted (Chapter 6).
Engine misses throughout driving speed range
m
mFuel filter clogged and/or impurities in the fuel system (Chapter 1).
m mLow fuel output at the injectors, or partially-blocked carburettor
jets (Chapter 4).
m mFaulty or incorrectly-gapped spark plugs (Chapter 1).
m mIncorrect ignition timing (Chapter 5).
m mCracked distributor cap, disconnected distributor HT leads, or
damaged distributor components (Chapter 1).
m mFaulty spark plug HT leads (Chapter 1).
m mFaulty emission system components (Chapter 6).
m mLow or uneven cylinder compression pressures (Chapter 2).
m mWeak or faulty ignition system (Chapter 5).
m mVacuum leak in fuel injection system, intake manifold or vacuum
hoses (Chapter 4).
Engine misfires on acceleration
m mSpark plugs fouled (Chapter 1).
m mFuel injection system or carburettor malfunctioning (Chapter 4).
m mFuel filter clogged (Chapters 1 and 4).
m mIncorrect ignition timing (Chapter 5).
m mIntake manifold air leak (Chapter 4).
Engine surges while holding accelerator steady
m
mIntake air leak (Chapter 4).
m mFuel pump faulty (Chapter 4).
m mLoose fuel injector harness connections (Chapters 4 and 6).
m mDefective ECU (Chapter 5).
Engine lacks power
m
mIncorrect ignition timing (Chapter 5).
m mExcessive play in distributor shaft (Chapter 5).
m mWorn rotor, distributor cap or HT leads (Chapters 1 and 5).
m mFaulty or incorrectly-gapped spark plugs (Chapter 1).
m mFuel injection system or carburettor malfunctioning (Chapter 4).
m mFaulty coil (Chapter 5).
m mBrakes binding (Chapter 1).
m mAutomatic transmission fluid level incorrect (Chapter 1).
m mClutch slipping (Chapter 8).
m mFuel filter clogged and/or impurities in the fuel system (Chapter 1).
m mEmission control system not functioning properly (Chapter 6).
m mLow or uneven cylinder compression pressures (Chapter 2).
Engine stalls
m
mIdle speed incorrect (Chapter 1).
m mFuel filter clogged and/or water and impurities in the fuel system
(Chapter 1).
m mDistributor components damp or damaged (Chapter 5).
m mFaulty emissions system components (Chapter 6).
m mFaulty or incorrectly-gapped spark plugs (Chapter 1).
m mFaulty spark plug HT leads (Chapter 1).
m mVacuum leak in the fuel injection system, intake manifold or
vacuum hoses (Chapter 4).
Engine backfires
m mEmissions system not functioning properly (Chapter 6).
m mIgnition timing incorrect (Chapter 5).
m mFaulty secondary ignition system (cracked spark plug insulator,
faulty plug HT leads, distributor cap and/or rotor) (Chapters 1 and 5).
m mFuel injection system or carburettor malfunctioning (Chapter 4).
m mVacuum leak at fuel injector(s), intake manifold or vacuum hoses
(Chapter 4).
m mValve clearances incorrect (Chapter 1), or valve(s) sticking or
damaged (Chapter 2).
Pinking or knocking engine sounds when
accelerating or driving uphill
m mIncorrect grade of fuel.
m mIgnition timing incorrect (Chapter 5).
m mFuel injection system or carburettor in need of adjustment (Chap-
ter 4).
m mDamaged spark plugs or HT leads, or incorrect type fitted (Chapter 1).
m mWorn or damaged distributor components (Chapter 5).
m mFaulty emission system (Chapter 6).
m mVacuum leak (Chapter 4).
Engine runs with oil pressure light on
Caution: Stop the engine immediately if the oil
pressure light comes on and establish the cause.
Running the engine while the oil pressure is low can
cause severe damage.
m mLow oil level (Chapter 1).
m mIdle speed too low (Chapter 1).
m mShort-circuit in wiring (Chapter 12).
m mFaulty oil pressure sender unit (Chapter 2).
m mWorn engine bearings and/or oil pump (Chapter 2).
Engine runs-on after switching off
m
mIdle speed too high (Chapter 1).
m mExcessive engine operating temperature (Chapter 3).
m mIncorrect fuel octane grade.
m mSpark plugs defective or incorrect grade (Chapter 1).
Engine electrical system
Battery will not hold charge
m
mAlternator drivebelt defective or not adjusted properly (Chapter 1).
m mElectrolyte level low (Chapter 1).
m mBattery terminals loose or corroded (Chapter 1).
m mAlternator not charging properly (Chapter 5).
m mLoose, broken or faulty wiring in the charging circuit (Chapter 5).
m mShort in vehicle wiring (Chapters 5 and 12).
m mInternally-defective battery (Chapters 1 and 5).
m mIgnition (no-charge) warning light bulb blown - on some early
models (Chapter 5)
Ignition (no-charge) warning light fails to go out
m mFaulty alternator or charging circuit (Chapter 5).
m mAlternator drivebelt defective or out of adjustment (Chapter 1).
m mAlternator voltage regulator inoperative (Chapter 5).
Ignition (no-charge) warning light fails to come on
when key is turned
m mWarning light bulb defective (Chapter 12).
m mFault in the printed circuit, wiring or bulbholder (Chapter 12).

REF•12Fault Finding
Fuel system
Excessive fuel consumption
m mDirty or clogged air filter element (Chapter 1).
m mIgnition timing incorrect (Chapter 5).
m mEmissions system not functioning properly (Chapter 6).
m mFuel injection internal parts or carburettor jets excessively worn or
damaged (Chapter 4).
m mLow tyre pressure or incorrect tyre size (Chapter 1).
m mUnsympathetic driving style, or unfavourable conditions.
Fuel leakage and/or fuel odour
Warning: Don’t drive the vehicle if a fuel leak is
suspected. Leaking fuel in the engine compartment
could catch fire.
m mLeak in a fuel feed or vent line (Chapter 4).
m mTank overfilled.
m mFuel injector or carburettor parts excessively worn, or fuel system
gaskets leaking (Chapter 4).
Cooling system
Overheating
m mInsufficient coolant in system (Chapter 1).
m mWater pump drivebelt defective or out of adjustment (Chapter 1).
m mRadiator matrix blocked, or grille restricted (Chapter 3).
m mThermostat faulty (Chapter 3).
m mRadiator cap not maintaining proper pressure (Chapter 3).
m mIgnition timing incorrect (Chapter 5).
Overcooling
m
mFaulty thermostat (Chapter 3).
External coolant leakage
m
mDeteriorated/damaged hoses; loose clamps (Chapters 1 and 3).
m mWater pump seal defective (Chapters 1 and 3).
m mLeakage from radiator matrix, heater matrix or header tank
(Chapter 3).
m mRadiator/engine block drain plugs or water jacket core plugs
leaking (Chapters 2 and 3).
Internal coolant leakage
m mLeaking cylinder head gasket (Chapter 2).
m mCracked cylinder bore or cylinder head (Chapter 2).
Coolant loss
m
mToo much coolant in system (Chapter 1).
m mCoolant boiling away because of overheating (see above).
m mInternal or external leakage (see above).
m mFaulty radiator cap (Chapter 3).
Poor coolant circulation
m
mInoperative water pump (Chapter 3).
m mRestriction in cooling system (Chapters 1 and 3).
m mWater pump drivebelt defective/out of adjustment (Chapter 1).
m mThermostat sticking (Chapter 3).
Clutch
Pedal travels to floor - no pressure or very little
resistance
m mMaster or slave cylinder faulty (Chapter 8).
m mFluid line burst or leaking (Chapter 8).
m mConnections leaking (Chapter 8).
m mNo fluid in reservoir (Chapter 1).
m mIf fluid is present in master cylinder dust cover, master cylinder rear
seal has failed (Chapter 8).
m mBroken release bearing or fork (Chapter 8).
Fluid in area of master cylinder dust cover, and on
pedal
m mRear seal failure in master cylinder (Chapter 8).
Fluid on slave cylinder
m
mSlave cylinder plunger seal faulty (Chapter 8).
Pedal feels “spongy” when depressed
m
mAir in system (Chapter 8).
Unable to select gears
m
mFaulty transmission (Chapter 7).
m mFaulty clutch plate (Chapter 8).
m mFork and bearing not assembled properly (Chapter 8).
m mFaulty pressure plate (Chapter 8).
m mPressure plate-to-flywheel bolts loose (Chapter 8).
Clutch slips (engine speed increases with no
increase in vehicle speed)
m mClutch plate worn (Chapter 8).
m mClutch plate is oil-soaked by leaking rear main seal (Chapter 8).
m mWarped pressure plate or flywheel (Chapter 8).
m mWeak diaphragm spring (Chapter 8).
m mClutch plate overheated.
Grabbing (chattering) as clutch is engaged
m
mOil on clutch plate lining, burned or glazed facings (Chapter 8).
m mWorn or loose engine or transmission mountings (Chapters 2
and 7A).
m mWorn splines on clutch plate hub (Chapter 8).
m mWarped pressure plate or flywheel (Chapter 8).
Noise in clutch area
m
mFork improperly fitted (Chapter 8).
m mFaulty release bearing (Chapter 8).
Clutch pedal stays on floor
m
mFork binding in housing (Chapter 8).
m mBroken release bearing or fork (Chapter 8).
High pedal effort
m
mFork binding in housing (Chapter 8).
m mPressure plate faulty (Chapter 8).
m mIncorrect-size master or slave cylinder fitted (Chapter 8).

REF•13
REF
Fault Finding
Automatic transmission
Note:Due to the complexity of the automatic transmission, it is
difficult for the home mechanic to properly diagnose and service this
unit. For problems other than the following, the vehicle should be
taken to a dealer or transmission specialist.
Fluid leakage
m mAutomatic transmission fluid is a deep red colour. Fluid leaks
should not be confused with engine oil, which can easily be blown
by airflow onto the transmission.
m mTo pinpoint a leak, first remove all built-up dirt and grime from the
transmission housing with degreasing agents and/or by steam-
cleaning. Then drive the vehicle at low speed, so airflow will not
blow the leak far from its source. Raise the vehicle and determine
where the leak is coming from. Common areas of leakage are:
a) Transmission sump (Chapters 1 and 7B)
b) Filler pipe (Chapter 7B)
c) Transmission fluid cooler lines (Chapter 7B)
d) Speedometer sensor (Chapter 7B)
Transmission fluid brown, or has a burned smell
m mTransmission fluid burned; fluid should be changed. May indicate
transmission internal fault (Chapters 1 and 7B).
Transmission will not kickdown with accelerator
pedal pressed to the floor
m mKickdown cable out of adjustment (Chapter 7B).
General shift mechanism problems
m
mChapter 7B deals with checking and adjusting the shift linkage on
automatic transmissions. Common problems which may be
attributed to poorly-adjusted linkage are:
a) Engine starting in gears other than Park or Neutral.
b) Indicator on selector lever pointing to a gear other than the one
actually being used.
c) Vehicle moves when in Park.
m mRefer to Chapter 7B for the shift linkage adjustment procedure.
Engine will start in gears other than Park or Neutral
m
mInhibitor switch malfunctioning (Chapter 7B).
Transmission slips, shifts roughly, is noisy, or has
no drive in forward or reverse gears
m mThere are many probable causes for the above problems, but the
home mechanic should be concerned with only one possibility -
fluid level. Before taking the vehicle to an automatic transmission
specialist, check the level and condition of the fluid as described in
Chapter 1. Correct the fluid level as necessary, or change the fluid
if needed. If the problem persists, have a professional diagnose the
probable cause.
Manual transmission
Vibration
m mDamaged propeller shaft (Chapter 8).
m mOut-of-round tyres (Chapter 1).
m mTyre out-of-balance (Chapters 1 and 10).
m mWorn propeller shaft universal joint (Chapter 8).
Noisy in neutral with engine running
m
mWorn clutch release bearing (Chapter 8).
m mWorn transmission input shaft bearing (Chapter 7A).
Noisy in one particular gear
m
mDamaged or worn constant-mesh gears.
m mDamaged or worn synchronisers.
Noisy in all gears
m
mInsufficient lubricant (Chapter 1).
m mDamaged or worn bearings.
m mWorn or damaged input gear shaft and/or output gear shaft.
Slips out of gear
m
mWorn or incorrectly-adjusted linkage (Chapter 7A).
m mTransmission-to-engine mounting bolts loose (Chapter 7A).
m mShift linkage binding (Chapter 7A).
m mWorn shift fork (Chapter 7A).
Leaks lubricant
m
mExcessive amount of lubricant in transmission (Chapters 1 and 7A).
m mLoose or broken input shaft bearing retainer (Chapter 7A).
m mInput shaft bearing retainer O-ring and/or lip seal damaged
(Chapter 7A).

REF•19
REF
Buying spare parts & vehicle identification numbers
Buying spare parts
Spare parts are available from many
sources; for example, BMW garages, other
garages and accessory shops, and motor
factors. Our advice regarding spare part
sources is as follows.
Officially-appointed BMW garages- This is
the best source for parts which are peculiar to
your vehicle, and which are not generally
available (eg complete cylinder heads, internal
transmission components, badges, interior
trim etc). It is also the only place at which you
should buy parts if the vehicle is still under
warranty. To be sure of obtaining the correct
parts, it will be necessary to give the storeman
the full Vehicle Identification Number, and if
possible, to take the old parts along for
positive identification. Many parts are
available under a factory exchange scheme -
any parts returned should always be clean. It
obviously makes good sense to go straight to
the specialists on your vehicle for this type of
part, as they are best equipped to supply you.
Other garages and accessory shops- These
are often very good places to buy materials
and components needed for the maintenance
of your vehicle (eg oil filters, spark plugs,
bulbs, drivebelts, oils and greases, touch-up
paint, filler paste, etc). They also sell general
accessories, usually have convenient opening
hours, charge lower prices, and can often be
found not far from home.
Motor factors- Good factors will stock all
the more important components which wearout comparatively quickly (eg exhaust
systems, brake pads, seals and hydraulic
parts, clutch components, bearing shells,
pistons, valves etc). Motor factors will often
provide new or reconditioned components on
a part-exchange basis - this can save a
considerable amount of money.
Vehicle identification
numbers
Modifications are a continuing and
unpublicised process in vehicle manufacture,
quite apart from major model changes. Spare
parts manuals and lists are compiled upon a
numerical basis, the appropriate identification
number or code being essential to correct
identification of the component concerned.When ordering spare parts, always give as
much information as possible. Quote the
vehicle model, year of manufacture, Vehicle
Identification Number and engine numbers, as
appropriate.
The Vehicle Identification Number (VIN)is
located on the right-hand front wheel arch
next to the front suspension strut upper
mounting, on the driver’s door, and on a plate
on top of the facia, just inside the windscreen
(see illustrations).
The engine number is stamped on a
machined face on the left-hand side of the
cylinder block, near the base of the oil level
dipstick tube.
The body numberis located on the seam
between the left-hand front wing and inner
panel.
The VIN (arrowed) is stamped on the
bulkheadThe VIN is also present on the edge of the
driver’s door

REF•22Glossary of Technical Terms
EEGR valveA valve used to introduce exhaust
gases into the intake air stream.
Electronic control unit (ECU)A computer
which controls (for instance) ignition and fuel
injection systems, or an anti-lock braking
system. For more information refer to the
Haynes Automotive Electrical and Electronic
Systems Manual.
Electronic Fuel Injection (EFI)A computer
controlled fuel system that distributes fuel
through an injector located in each intake port
of the engine.
Emergency brakeA braking system,
independent of the main hydraulic system,
that can be used to slow or stop the vehicle if
the primary brakes fail, or to hold the vehicle
stationary even though the brake pedal isn’t
depressed. It usually consists of a hand lever
that actuates either front or rear brakes
mechanically through a series of cables and
linkages. Also known as a handbrake or
parking brake.
EndfloatThe amount of lengthwise
movement between two parts. As applied to a
crankshaft, the distance that the crankshaft
can move forward and back in the cylinder
block.
Engine management system (EMS)A
computer controlled system which manages
the fuel injection and the ignition systems in
an integrated fashion.
Exhaust manifoldA part with several
passages through which exhaust gases leave
the engine combustion chambers and enter
the exhaust pipe.
FFan clutchA viscous (fluid) drive coupling
device which permits variable engine fan
speeds in relation to engine speeds.Feeler bladeA thin strip or blade of hardened
steel, ground to an exact thickness, used to
check or measure clearances between parts.
Firing orderThe order in which the engine
cylinders fire, or deliver their power strokes,
beginning with the number one cylinder.
Flywheel A heavy spinning wheel in which
energy is absorbed and stored by means of
momentum. On cars, the flywheel is attached
to the crankshaft to smooth out firing
impulses.
Free playThe amount of travel before any
action takes place. The “looseness” in a
linkage, or an assembly of parts, between the
initial application of force and actual
movement. For example, the distance the
brake pedal moves before the pistons in the
master cylinder are actuated.
FuseAn electrical device which protects a
circuit against accidental overload. The typical
fuse contains a soft piece of metal which is
calibrated to melt at a predetermined current
flow (expressed as amps) and break the
circuit.
Fusible linkA circuit protection device
consisting of a conductor surrounded by
heat-resistant insulation. The conductor is
smaller than the wire it protects, so it acts as
the weakest link in the circuit. Unlike a blown
fuse, a failed fusible link must frequently be
cut from the wire for replacement.
GGapThe distance the spark must travel in
jumping from the centre electrode to the sideelectrode in a spark plug. Also refers to the
spacing between the points in a contact
breaker assembly in a conventional points-
type ignition, or to the distance between the
reluctor or rotor and the pickup coil in an
electronic ignition.
GasketAny thin, soft material - usually cork,
cardboard, asbestos or soft metal - installed
between two metal surfaces to ensure a good
seal. For instance, the cylinder head gasket
seals the joint between the block and the
cylinder head.
GaugeAn instrument panel display used to
monitor engine conditions. A gauge with a
movable pointer on a dial or a fixed scale is an
analogue gauge. A gauge with a numerical
readout is called a digital gauge.
HHalfshaftA rotating shaft that transmits
power from the final drive unit to a drive
wheel, usually when referring to a live rear
axle.
Harmonic balancerA device designed to
reduce torsion or twisting vibration in the
crankshaft. May be incorporated in the
crankshaft pulley. Also known as a vibration
damper.
HoneAn abrasive tool for correcting small
irregularities or differences in diameter in an
engine cylinder, brake cylinder, etc.
Hydraulic tappetA tappet that utilises
hydraulic pressure from the engine’s
lubrication system to maintain zero clearance
(constant contact with both camshaft and
valve stem). Automatically adjusts to variation
in valve stem length. Hydraulic tappets also
reduce valve noise.
IIgnition timingThe moment at which the
spark plug fires, usually expressed in the
number of crankshaft degrees before the
piston reaches the top of its stroke.
Inlet manifoldA tube or housing with
passages through which flows the air-fuel
mixture (carburettor vehicles and vehicles with
throttle body injection) or air only (port fuel-
injected vehicles) to the port openings in the
cylinder head.
Exhaust manifold
Feeler blade
Adjusting spark plug gap
Gasket
EGR valve

REF•24Glossary of Technical Terms
automatic transmission, a switch that
prevents starting if the vehicle is not in Neutral
or Park.
StrutSee MacPherson strut.
TTappetA cylindrical component which
transmits motion from the cam to the valve
stem, either directly or via a pushrod and
rocker arm. Also called a cam follower.
ThermostatA heat-controlled valve that
regulates the flow of coolant between the
cylinder block and the radiator, so maintaining
optimum engine operating temperature. A
thermostat is also used in some air cleaners in
which the temperature is regulated.
Thrust bearingThe bearing in the clutch
assembly that is moved in to the release levers
by clutch pedal action to disengage the
clutch. Also referred to as a release bearing.
Timing beltA toothed belt which drives the
camshaft. Serious engine damage may result
if it breaks in service.
Timing chainA chain which drives the
camshaft.
Toe-inThe amount the front wheels are
closer together at the front than at the rear. On
rear wheel drive vehicles, a slight amount of
toe-in is usually specified to keep the front
wheels running parallel on the road by
offsetting other forces that tend to spread the
wheels apart.
Toe-outThe amount the front wheels are
closer together at the rear than at the front. Onfront wheel drive vehicles, a slight amount of
toe-out is usually specified.
ToolsFor full information on choosing and
using tools, refer to the Haynes Automotive
Tools Manual.
TracerA stripe of a second colour applied to
a wire insulator to distinguish that wire from
another one with the same colour insulator.
Tune-upA process of accurate and careful
adjustments and parts replacement to obtain
the best possible engine performance.
TurbochargerA centrifugal device, driven by
exhaust gases, that pressurises the intake air.
Normally used to increase the power output
from a given engine displacement, but can
also be used primarily to reduce exhaust
emissions (as on VW’s “Umwelt” Diesel
engine).
UUniversal joint or U-jointA double-pivoted
connection for transmitting power from a
driving to a driven shaft through an angle. A U-
joint consists of two Y-shaped yokes and a
cross-shaped member called the spider.
VValveA device through which the flow of
liquid, gas, vacuum, or loose material in bulk
may be started, stopped, or regulated by a
movable part that opens, shuts, or partiallyobstructs one or more ports or passageways.
A valve is also the movable part of such a
device.
Valve clearanceThe clearance between the
valve tip (the end of the valve stem) and the
rocker arm or tappet. The valve clearance is
measured when the valve is closed.
Vernier caliperA precision measuring
instrument that measures inside and outside
dimensions. Not quite as accurate as a
micrometer, but more convenient.
ViscosityThe thickness of a liquid or its
resistance to flow.
VoltA unit for expressing electrical “pressure”
in a circuit. One volt that will produce a current
of one ampere through a resistance of one
ohm.
WWeldingVarious processes used to join metal
items by heating the areas to be joined to a
molten state and fusing them together. For
more information refer to the Haynes
Automotive Welding Manual.
Wiring diagramA drawing portraying the
components and wires in a vehicle’s electrical
system, using standardised symbols. For
more information refer to the Haynes
Automotive Electrical and Electronic Systems
Manual.

REF•25
REF
Index
Note: References throughout this index relate to Chapter•page number
A
ABS - 9•2
Accelerator cable - 4•9
Acknowledgements - 0•4
Aerial - 12•4
Air bags - 0•5
Air cleaner - 4•8
Air conditioning system - 3•2, 3•7, 3•8,
3•9, 3•10
Air filter - 1•20
Air gap - 5•7
Air intake system - 4•2, 4•14
Airflow meter - 4•15, 6•4
Alternator - 5•10
Anti-lock Braking system (ABS) - 9•2
Anti-roll bar - 10•4, 10•9
Anti-theft audio system - 0•7
Antifreeze - 1•3, 1-8, 3•2
Asbestos - 0•5
ATF - 1•3, 1•13, 1•23
Automatic choke - 4•13
Automatic transmission- 7B•1et seq
Automatic transmission fault finding -
7B•4, REF•13
Automatic transmission fluid - 1•3, 1•13,
1•23
B
Backfire - REF•11
Balljoints - 10•7
Battery - 0•5, 1•16, 5•2
Battery fault - REF•11
Big-end bearings - 2B•17, 2B•21
Bleeding brakes - 9•14
Bleeding clutch - 8•4
Bleeding power steering - 10•16Block - 2B•14, 2B•15
Blower motor - 3•7
Body corrosion - REF•4
Body electrical systems- 12•1et seq
Bodywork and fittings- 11•1et seq
Bonnet - 11•4
Boot lid - 11•6
Boots - 8•9, 10•13
Brake fluid - 1•3, 1•9
Brake lines and hoses - 1•22, 9•13
Braking system- 1•22, 9•1et seq,REF•1,
REF•2, REF•3
Braking system fault finding - REF•14
Bulbs - 12•6
Bumpers - 11•6
Burning - 0•5
C
Cables - 4•9, 5•2, 7B•3, 9•12
Calipers - 9•4
Cam followers - 2B•11
Camshaft - 2A•12, 2B•11
Carburettor - 4•10, 4•11
Carpets - 11•2
Catalytic converter - 4•20, 6•6
Central locking - 12•8
Charging - 1•17, 5•9
Chemicals - REF•18
Choke - 4•13
Clutch and driveline- 8•1et seq
Clutch fault finding - REF•12
Clutch fluid - 1•3, 1•9
CO level adjustment - 1•15, REF•4
Coil - 5•5
Coil springs - 10•7, 10•9
Cold start injectors - 4•17, 4•18
Compression check - 2B•4Compressor - 3•8
Condenser - 3•9
Connecting rods -2B•12, 2B•16, 2B•21
Constant velocity (CV) joint - 8•2, 8•8, 8•9
Continuity check - 12•2
Control arm - 10•4, 10•5
Conversion factors - REF•17
Coolant - 1•3, 1•8
Coolant pump - 3•5
Coolant temperature sender unit - 3•6
Coolant temperature sensor - 6•2
Cooling fan - 3•4
Cooling, heating and air conditioning
systems- 1•21, 1•24, 3•1et seq
Cooling system fault finding - REF•12
Crankshaft - 2A•12, 2A•13, 2A•19, 2B•13,
2B•17, 2B•19, 2B•20
Cruise control - 12•3, 12•8
Crushing - 0•5
Cushion - 11•9
CV joints - 8•2, 8•8, 8•9
Cylinder head - 2A•13, 2B•7, 2B•10, 2B•12
Cylinder honing - 2B•15
D
Dents in bodywork - 11•2
Differential (final drive) - 8•2, 8•10, 8•11
Differential oil -1•3, 1•19, 1•26
Direction indicators - 12•2, 12•3
Discs - 1•22, 9•5
Distributor - 1•18, 5•4
Door - 11•6, 11•8, REF•2
Drivebelts - 1•14
Driveplate - 2A•18
Driveshafts - 1•22, 8•2, 8•9
Drums - 1•23

REF•26Index
E
Earth check - 12•2
Electric fan - 3•4
Electric shock - 0•5
Electric windows - 12•9
Electrical equipment - REF•2
Electrical system fault finding - 12•1
Electronic control system - 4•3, 4•14
Electronic control unit (ECU) - 6•1
Engine fault finding - REF•10
Engine tune-up - 1•7
Engine electrical systems- 5•1et seq
Engine electrical systems fault finding -
REF•11
Engine management and emission control
systems- 6•1et seq
Engine oil - 1•3, 1•7, 1•11
Environmental considerations - REF•8
Evaporative emissions control (EVAP)
system - 1•26, 6•5
Evaporator - 3•10
Exhaust emission checks - REF•4
Exhaust manifold - 2A•6
Exhaust system - 1•21, 4•20, REF•3
F
Fan - 3•4, 3•5
Fault finding- REF•9et seq
Fault finding - automatic transmission -
7B•2, REF•13
Fault finding - braking system - REF•14
Fault finding - clutch - REF•12
Fault finding - cooling system - REF•12
Fault finding - electrical system - 12•1,
REF•11
Fault finding - engine - REF•10
Fault finding - fuel system - 4•21, REF•12
Fault finding - manual transmission -
REF•13
Fault finding - suspension and steering -
REF•15
Filling - 11•3
Final drive - 8•2, 8•10, 8•11
Final drive oil - 1•3, 1•19, 1•26
Fire - 0•5
Flexible coupling - 8•7
Fluid level checks - 1•7
Fluid seals - 7B•5
Flywheel - 2A•18
Fuel and exhaust systems- 1•20, 4•1et
seq,REF•4
Fuel system fault finding - REF•12
Fuel filter - 1•25
Fuel hoses - 1•14
Fuel injection system - 4•3, 4•14
Fuel injection system - fault finding - 4•21
Fuel injectors - 4•18
Fuel level sender unit - 4•5, 4•6
Fuel lines and fittings - 4•7
Fuel pressure - 4•3
Fuel pressure regulator - 4•16
Fuel pump - 4•3, 4•4, 4•5
Fuel tank - 4•7, 4•8
Fume or gas intoxication - 0•5
Fuses - 12•2
G
Gaiters - 1•22, 8•9, 10•13
Gashes in bodywork - 11•2
Gaskets - REF•8
Gear lever - 7A•1
Gearbox - SeeManual transmission
Gearbox oil - 1•3, 1•19, 1•25
General engine overhaul procedures-
2B•1et seq
Glass - 11•4, 11•8
Glossary of technical terms - REF•20
Grille - 11•4
H
Handbrake - 1•23, 9•2, 9•12, REF•1
Handbrake fault - REF•14
Handles - 11•8
Hazard warning flasher - 12•2
HC emissions - REF•4
Headlights - 12•3, 12•5, 12•6
Heated rear window - 12•8
Heater - 3•2, 3•7, 3•8
Hinges - 11•4
HT leads - 1•18
Hubs - 10•8, 10•11, REF•3
Hydraulic servo - 9•11
Hydraulic tappets - 2B•11
Hydrofluoric acid - 0•5
I
Idle air stabiliser valve - 4•18
Idle speed adjustment - 1•15
Ignition coil - 5•5
Ignition control unit - 5•6, 5•7
Ignition sensors - 5•8
Ignition switch - 12•3
Ignition system - 5•3
Ignition timing - 5•4
Ignition timing sensors - 6•4
Impulse generator - 5•6, 5•7
In-car engine repair procedures- 2A•1et
seq
Indicators - 12•2, 12•3
Information sensors - 6•2
Injectors - 4•18
Input shaft - 7A•2
Instrument cluster - 12•4
Instrument panel language display - 0•7
Intake manifold - 2A•4
Intermediate shaft - 2A•12, 2B•14, 2B•19
Introduction to the BMW 3- and 5-Series -
0•4
J
Jacking - 0•8
Joint mating faces - REF•8
Jump starting - 0•9
K
Kickdown cable - 7B•3
L
L-Jetronic fuel injection system - 4•14,
4•19
Language display - 0•7
Latch - 11•8
Leaks - 0•10, 7B•3, REF•12, REF•13
Locknuts, locktabs and washers - REF•8
Locks - 11•4, 11•8
Lubricants - REF•18
M
Main bearings - 2B•17, 2B•19
Manifolds - 2A•4, 2A•6
Manual transmission- 7A•1et seq
Manual transmission fault finding - REF•13
Manual transmission oil - 1•3, 1•19, 1•25
Master cylinder - 8•3, 9•9
Mechanical fan - 3•4, 3•5
Mirrors - 11•8, REF•1
Misfire - REF•11
Mixture - REF•4
MOT test checks- REF•1 et seq
Motronic engine management system -
6•1
Motronic fuel injection system - 4•14, 4•19
Mountings - 2A•19, 7A•3
O
Oil - differential - 1•19, 1•26
Oil - engine - 1•3, 1•7, 1•11
Oil - final drive - 1•3
Oil - manual transmission - 1•3, 1•19, 1•25
Oil filter - 1•11, 1•12
Oil pump - 2A•16
Oil seals - 2A•12, 2A•13, 2A•19, 2B•20,
7A•2, 7B•5, 8•10, 8•12, REF•8
Open-circuit - 12•2
Output shaft - 7A•2, 7B•5
Overcooling - REF•12
Overheating - REF•12
Oxygen sensor - 6•2
P
Pads - 9•2, 9•3
Pedals - 8•3, 9•13
Pinion oil - 8•12
Pinking - REF•11
Piston rings - 2B•18
Pistons - 2B•12, 2B•16, 2B•21
Plastic components - 11•3
Poisonous or irritant substances - 0•5
Position sensors - 5•8
Positive crankcase ventilation (PCV)
system - 6•4
Power steering - 1•14, 10•15, 10•16
Power steering fluid - 1•12
Propeller shaft - 8•2, 8•6, 8•8
Pulse sensor - 5•8
Purge valve - 6•5