1991 BMW 5 SERIES four wheel drive

BMW 3- & 5-Series
Service and Repair Manual
A K Legg LAE MIMI and Larry Warren
Models covered
3-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 models
5-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 covered
1596 cc, 1766 cc, 1795 cc, 1990 cc, 2494 cc, 2788 cc, 2986 cc & 3430 cc
Does not cover Diesel, dohc or V8 engines, or four-wheel-drive models
© Haynes Publishing 1997
A book in the Haynes Service and Repair Manual Series
All rights reserved. No part of this book may be reproduced or transmitted
in any form or by any means, electronic or mechanical, including
photocopying, recording or by any information storage or retrieval system,
without permission in writing from the copyright holder.
ISBN1 85960 236 3
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library.Printed by J H Haynes & Co. Ltd, Sparkford, Nr Yeovil,Somerset
BA22 7JJ, England
Haynes Publishing
Sparkford, Nr Yeovil, Somerset BA22 7JJ, England
Haynes North America, Inc
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1 2 3

0•4Introduction
The E30 3-Series range first became
available in the UK in March 1983, and
continued in production until April 1991, when
the revised E36 3-Series range (not covered
by this manual) was introduced. Convertible
and Touring (Estate) models were introduced
for 1988, and these models have continued in
E30 form to date.
The E28 5-Series models were introduced
in October 1981, and were superseded in
June 1988 by the revised E34 5-Series range,
Touring versions of which became available
from 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 are
equipped with single overhead cam in-line
four- and six-cylinder engines. Early 316 and
518 models are fitted with carburettors, but all
other models are fitted with fuel injection
systems. Transmissions are a five-speed
manual, or three- or four-speed automatic.
The transmission is mounted to the back of
the engine, and power is transmitted to the
fully-independent rear axle through a two-
piece propeller shaft. The final drive unit is
bolted solidly to a frame crossmember, and
drives the rear wheels through driveshaftsequipped with inner and outer constant
velocity joints.
The front suspension is of MacPherson
strut type, with the coil spring/shock absorber
unit making up the upper suspension link. The
rear suspension is made up of coil spring-
over-shock absorber struts, or coil springs
and conventional shock absorbers,
depending on model.
The brakes are disc type at the front, with
either drums or discs at the rear, depending
on model. Servo assistance is standard on all
models. Some later models are equipped with
an Anti-lock Braking System (ABS).
All models are manufactured to fine limits,
and live up to the BMW reputation of quality
workmanship. Although many of the models
covered by this manual appear complex at
first sight, they should present no problems to
the home mechanic.
Note for UK readers
The greater part of this manual was
originally written in the USA. Some of the
photographs used are of American-market
models, but the procedures given are fully
applicable to right-hand-drive models (or have
been amended where necessary).
Acknowledgements
Thanks are due to Champion Spark Plug,
who supplied the illustrations showing spark
plug conditions. Thanks are also due to
Sykes-Pickavant Limited, who provided some
of the workshop tools, and to all those people
at Sparkford who helped in the production of
this manual. Technical writers who
contributed to this project include Robert
Maddox, Mark Ryan and Mike Stubblefield.
We take great pride in the accuracy of
information given in this manual, but
vehicle manufacturers make alterations
and design changes during the production
run of a particular vehicle of which they do
not inform us. No liability can be accepted
by the authors or publishers for loss,
damage or injury caused by any
errors in, or omissions from, the
information given.
Project vehicles
The main project vehicle used in the
preparation of this manual for the UK market
was a 1988 BMW 318i with an M40/B18
engine.
Introduction to the BMW 3- and 5-Series
BMW 320i Saloon (E30)

0•8Roadside Repairs
Jacking and wheel
changing
The jack supplied with the vehicle should
be used only for raising the vehicle when
changing a tyre or placing axle stands under
the frame.
Warning:Never crawl under the
vehicle or start the engine when
this jack is being used as the
only means of support.
When changing a wheel, the vehicle should
be on level ground, with the handbrake firmly
applied, and the wheels chocked. Select
reverse gear (manual transmission) or Park
(automatic transmission). Prise off the hub
cap (if equipped) using the tapered end of the
wheel brace. Loosen the wheel bolts half a
turn, leaving them in place until the wheel is
raised off the ground.
Position the head of the jack under the side
of the vehicle, making sure it engages with thepocket made for this purpose (just behind the
front wheel, or forward of the rear wheel).
Engage the wheel brace handle and turn it
clockwise until the wheel is raised off the
ground. Unscrew the bolts, remove the wheel
and fit the spare.
Refit the wheel bolts and tighten them
finger-tight. Lower the vehicle by turning the
wheel brace anti-clockwise. Remove the jack
and tighten the bolts in a diagonal pattern to
the torque listed in the Chapter 1
Specifications. If a torque wrench is not
available, have the torque checked by a BMW
dealer or tyre fitting specialist as soon as
possible. Refit the hubcap.
Towing
Vehicles with manual transmission can be
towed with all four wheels on the ground, if
necessary. Automatic transmission-equipped
vehicles can only be towed with all fourwheels on the ground providing that the
speed does not exceed 35 mph and the
distance is not over 50 miles, otherwise
transmission damage can result. For
preference, regardless of transmission type,
the vehicle should be towed with the driven
(rear) wheels off the ground.
Proper towing equipment, specifically
designed for the purpose, should be used,
and should be attached to the main structural
members of the vehicle, not to the bumpers or
bumper brackets. Sling-type towing
equipment must notbe used on these
vehicles.
Safety is a major consideration while
towing. The handbrake should be released,
and the transmission should be in neutral. The
steering must be unlocked (ignition switch
turned to position “1”). Remember that
power-assisted steering (where fitted) and the
brake servo will not work with the engine
switched off.
Jacking, towing and wheel changing

Tyre pressures (cold) - bars (psi)Front Rear
3-Series, E30
316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 (28) 2.1 (30)
316i
Saloon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 (29) 2.1 (30)
Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 (29) 2.2 (32)
318i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 (26) 1.9 (28)
320i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 (28) 2.0 (29)
325i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 (32) 2.3 (33)
5-Series, E28 (“old-shape”)
518 and 518i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 (29) 2.0 (29)
525i and 528i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 (32) 2.2 (32)
535i and M535i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 (33) 2.5 (36)
5-Series, E34 (“new-shape”)
518i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 (29) 2.0 (29)
520i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 (32) 2.1 (30)
525i, 530i and 535i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 (29) 2.3 (33)
Torque wrench settingsNm
Automatic transmission sump bolts
Three-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 to 9
Four-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 7
Spark plugs
M10 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 to 30
Except M10 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 to 33
Oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 to 33
Wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Lubricants and fluids
Component or system Lubricant type/specification
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Multigrade engine oil, viscositySAE 10W/40 to 20W/50, to API SG
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ethylene glycol-based antifreeze with corrosion inhibitors
Manual transmission* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear oil, viscosity SAE 80 to API-GL4, or single-grade mineral-based
engine oil, viscosity SAE 20, 30 or 40 to API-SG
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexron ll type ATF
Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BMW-approved hypoid gear oil, viscosity SAE 90**
Brake and clutch hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic brake fluid to SAE J 1703 or DOT 4
Power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dexron ll type ATF
* E34 520i & 525i with air conditioning, E34 530i & 535i - Dexron II type ATF)
** Only available in bulk; refer to your BMW dealer
Capacities*
1•3
1
Engine oil
M10 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 litres
M20 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3 litres
M30 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8 litres
M40 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.0 litres
Cooling system
M10 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 litres
M20 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 litres
M30 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.0 litres
M40 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 litres
Fuel tank
3-Series, E30
Saloon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 litres (early),
64 litres (later)
Estate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 litres (early),
70 litres (later)
5-Series
E28 (“old-shape”) . . . . . . . . . . . . . . . . . . . . . . . . 70 litres
E34 (“new-shape”) . . . . . . . . . . . . . . . . . . . . . . . 81 litresManual transmission
ZF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 litres
Getrag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 to 1.5 litres
Automatic transmission (refill)
3-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 litres
4-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 litres
Final drive capacity (drain and refill)
3-Series, E30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 litres
5-Series, E28 (“old-shape”) . . . . . . . . . . . . . . . . . . 0.9 litres
5-Series, E34 (“new-shape”) . . . . . . . . . . . . . . . . . 1.7 litres
*All capacities approximate
Servicing Specifications

Caution: Do not overfill the
reservoir. If too much fluid is
added, remove the excess with a
clean syringe. Refit the cap.
7If frequent topping-up is needed, check the
power steering hoses and connections for
leaks and wear (see Section 10).
8Check the condition and tension of the
drivebelt (see Section 11).
8 Automatic transmission fluid
level check
1
Caution: The use of transmission
fluid other than the type listed in
this Chapter’s Specifications
could result in transmission
malfunctions or failure.
1The automatic transmission fluid should be
carefully maintained. Low fluid level can lead
to slipping or loss of drive, while overfilling
can cause foaming and loss of fluid. Either
condition can cause transmission damage.
2Since transmission fluid expands as it heats
up, the fluid level should only be checked
when the transmission is warm (at normal
operating temperature). If the vehicle has just
been driven over 20 miles (32 km), the
transmission can be considered warm. You
can also check the fluid level when the
transmission is cold. If the vehicle has not
been driven for over five hours and the fluid is
about room temperature (20°C), the
transmission is cold. However, the fluid level
is normally checked with the transmission
warm, to ensure accurate results.
Caution: If the vehicle has just
been driven for a long time at
high speed or in city traffic, in hot
weather, or if it has been pulling
a trailer, an accurate fluid level reading
cannot be obtained. Allow the trans-
mission to cool down for about 30 minutes.
3Immediately after driving the vehicle, park it
on a level surface, apply the handbrake and
start the engine. While the engine is idling,
depress the brake pedal and move theselector lever through all the gear ranges,
beginning and ending in Park.
4The automatic transmission dipstick tube is
located in the left rear corner of the engine
compartment.
5With the engine still idling, pull the dipstick
out of the tube (see illustration), wipe it off
with a clean rag, push it all the way back into
the tube and withdraw it again, then note the
fluid level.
6The level should be between the two marks
(see illustration). If the level is low, add the
specified automatic transmission fluid through
the dipstick tube - use a clean funnel,
preferably equipped with a fine mesh filter, to
prevent spills.
Caution: Be careful not to
introduce dirt into the
transmission when topping up.
7Add just enough of the recommended fluid
to fill the transmission to the proper level. It
takes about half a litre to raise the level from
the low mark to the high mark when the fluid
is hot, so add the fluid a little at a time, and
keep checking the level until it’s correct.
8The condition of the fluid should also be
checked along with the level. If the fluid is
black or a dark reddish-brown colour, or if it
smells burned, it should be changed (see
Section 28). If you are in doubt about its
condition, purchase some new fluid, and
compare the two for colour and smell.
9 Tyre rotation
1
1The tyres can be rotated at the specified
intervals, or whenever uneven wear is noticed.
However, bear in mind that if rotation
succeeds in making all the tyres wear evenly,
you will eventually have to renew all four at
once. Since the vehicle will be raised and the
wheels removed anyway, check the brakes
also (see Section 26). Note: Even if you don’t
rotate the tyres, at least check the wheel bolt
tightness.
2It is recommended that the tyres be rotatedin a specific pattern (see illustration)so that
their direction of rotation remains the same.
3Refer to the information in “Jacking and
towing”at the front of this manual for the
proper procedure to follow when raising the
vehicle and changing a tyre.
4The vehicle must be raised on a hoist or
supported on axle stands to get all four tyres
off the ground. Make sure the vehicle is safely
supported!
5After the rotation procedure is finished,
check and adjust the tyre pressures as
necessary, and be sure to check the wheel
bolt tightness.
10 Underbonnet hose check
and renewal
3
Warning: Renewal of air
conditioning hoses must be left
to a dealer service department or
air conditioning specialist having
the equipment to depressurise the system
safely. Never disconnect air conditioning
hoses or components until the system has
been depressurised.
General
1High temperatures under the bonnet can
cause deterioration of the rubber and plastic
hoses used for various systems. Periodic
inspection should be made for cracks, loose
clamps, material hardening, and leaks.
2Information specific to the cooling system
can be found in Section 22, while the braking
system is covered in Section 26.
3Most (but not all) hoses are secured with
clamps. Where clamps are used, check to be
sure they haven’t lost their tension, allowing
the hose to leak. If clamps aren’t used, make
sure the hose has not expanded and/or
hardened where it slips over the fitting,
allowing it to leak.
Vacuum hoses
4It’s quite common for vacuum hoses,
especially those in the emissions system, to
be colour-coded or identified by coloured
1•13
9.2 The tyre rotation pattern for these
models8.6 With the fluid hot, the level should be
kept between the two dipstick notches,
preferably near the upper one8.5 The automatic transmission fluid
dipstick (arrowed) is located near the
bulkhead on the left side of the engine
compartment
1
Every 6000 miles

no cause for concern. Make sure that any fluid
noted is from the struts/shocks, and not from
any other source. If leakage is noted, renew
the struts or shock absorbers in axle pairs (or
as a full set).
7Check the struts/shock absorbers to be
sure that they are securely mounted and
undamaged. Check the upper mountings for
damage and wear. If damage or wear is
noted, renew the struts or shock absorbers.
8If the struts or shock absorbers must be
renewed, refer to Chapter 10 for the
procedure. Always renew both units on the
same axle, or the safety of the vehicle may be
compromised. If possible, renew all four as a
set.
Steering and suspension check
9Inspect the steering system components
for damage and distortion. Look for leaks and
damaged seals, boots and fittings.
10Clean the lower end of the steering
knuckle. Have an assistant grasp the lower
edge of the tyre and move the wheel in and
out, while you look for movement at the
steering knuckle-to-axle arm balljoints.
Inspect the balljoint boots for tears (see
illustration). If there is any movement, or the
boots are torn or leaking, the balljoint(s) must
be renewed.
11Grasp each front tyre at the front and rear
edges, push in at the front, pull out at the rear
and feel for play in the steering linkage. If any
free play is noted, check the steering gear
mountings and the track rod balljoints for
looseness. If the steering gear mountings are
loose, tighten them. If the track rods are
loose, the balljoints may be worn (check to
make sure the nuts are tight). Additional
steering and suspension system information
can be found in Chapter 10.
25 Driveshaft gaiter check
1
1The driveshaft gaiters are very important
because they prevent dirt, water and foreign
material from entering and damaging the
constant velocity (CV) joints. External oil and
grease contamination can cause the gaitermaterial to deteriorate prematurely, so it’s a
good idea to wash the gaiters with soap and
water.
2Inspect the gaiters for tears and cracks, as
well as for loose clamps (see illustration). If
there is any evidence of cracks or leaking
lubricant, the gaiter must be renewed (see
Chapter 8).
26 Brake system check
2
Warning: Dust produced by lining
wear and deposited on brake
components may contain
asbestos, which is hazardous to
your health. Do not blow it out with
compressed air, and don’t inhale it! Do not
use petroleum-based solvents to remove
the dust. Brake system cleaner or
methylated spirit should be used to flush
the dust into a drain pan. After the brake
components are wiped with a damp rag,
dispose of the contaminated rag(s) and the
drain pan contents into a covered and
labelled container. Try to use asbestos-
free new parts whenever possible.
Note:In addition to the specified intervals, the
brake system should be inspected each time
the wheels are removed or a malfunction is
indicated. Because of the obvious safety con-
siderations, the following brake system checks
are some of the most important maintenance
procedures you can perform on your vehicle.
Symptoms of brake system
problems
1The disc brakes have built-in electrical wear
indicators which cause a warning light on the
dash to come on when they’re worn to the
renewal point. When the light comes on,
renew the pads immediately, or expensive
damage to the brake discs could result.
2Any of the following symptoms could
indicate a potential brake system defect:
a) Vehicle pulls to one side when the brake
pedal is depressed
b) Brakes make squealing or dragging noises
when applied
c) Brake pedal travel excessived) Brake pedal pulsates (normal if ABS is
working)
e) Brake fluid leaks (usually on the inner side
of the tyre or wheel)
3If any of these conditions are noted, inspect
the brake system immediately.
Brake lines and hoses
Note: Steel brake pipes are used throughout
the brake system, with the exception of
flexible, reinforced hoses at the front wheels
and as connectors at the rear axle. Periodic
inspection of all these lines is very important.
4Park the vehicle on level ground, and
switch off the engine. Remove the wheel
covers. Loosen, but do not remove, the bolts
on all four wheels.
5Raise the vehicle and support it securely on
axle stands.
6Remove the wheels (see “Jacking and
towing” at the front of this book, or refer to
your owner’s handbook, if necessary).
7Check all brake lines and hoses for cracks,
chafing of the outer cover, leaks, blisters, and
distortion. Check the brake hoses at front and
rear of the vehicle for softening, cracks,
bulging, or wear from rubbing on other
components. Check all threaded fittings for
leaks, and make sure the brake hose
mounting bolts and clips are secure.
8If leaks or damage are discovered, they
must be repaired immediately. Refer to
Chapter 9 for detailed brake system repair
procedures.
Disc brakes
9If it hasn’t already been done, raise the
vehicle and support it securely on axle stands.
Remove the front wheels.
10The disc brake calipers, containing the
pads, are now visible. Each caliper has an
outer and an inner pad - all pads should be
checked.
11Note the pad thickness by looking
through the inspection hole in the caliper (see
illustration). If the lining material is 2.0 mm
thick or less, or if it is tapered from end to
end, the pads should be renewed (see
Chapter 9). Keep in mind that the lining
1•22
26.11 Look through the caliper inspection
window to inspect the brake pads - the
pad lining which rubs against the disc can
also be inspected by looking through each
end of the caliper25.2 Gently probe the driveshaft boots to
check for cracks24.10 Inspect the balljoint boots for tears
(arrowed)
Every 12 000 miles

2A
General
Displacement
3-series, E30 body style
316i (1988 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1596 cc (M40/4-cylinder engine)
316 (1983 to 1988) and 318i (1983 to 1987) . . . . . . . . . . . . . . . . 1766 cc (M10/4-cylinder engine)
318i (1987 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1796 cc (M40/4-cylinder engine)
320i (1987 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990 cc (M20/6-cylinder engine)
325i (1987 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2494 cc (M20/6-cylinder engine)
5-series, E28 body style (“old-shape”)
518 (1981 to 1985) and 518i (1985 to 1988) . . . . . . . . . . . . . . . . 1766 cc (M10/4-cylinder engine)
525i (1981 to 1988) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2494 cc (M30/6-cylinder engine)
528i (1981 to 1988) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2788 cc (M30/6-cylinder engine)
535i (1985 to 1988) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3430 cc (M30/6-cylinder engine)
M535i (1985 to 1988) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3430 cc (M30/6-cylinder engine)
5-series, E34 body style (“new-shape”)
518i (1990 to 1993) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1796 cc (M40/4-cylinder engine)
520i (1988 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990 cc (M20/6-cylinder engine)
525i (1988 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2494 cc (M20/6-cylinder engine)
530i (1988 to 1991) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2986 cc (M30/6-cylinder engine)
535i (1988 to 1993) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3430 cc (M30/6-cylinder engine)
Firing order
Four-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2
Six-cylinder engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5-3-6-2-4
Lubrication system
Oil pressure (all engines)
At idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 2.0 bars
Running (for example, at 4000 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . 4 bars or above (typically)
Oil pump rotor clearance - M40 engine
(body-to-outer rotor/outer rotor-to-inner rotor) . . . . . . . . . . . . . . . . . . . 0.12 mm to 0.20 mm
Oil pump pressure relief valve spring length - M40 engine . . . . . . . . . . 84.1 mm
Chapter 2 Part A:
In-car engine repair procedures
Camshaft - removal, inspection and refitting . . . . . . See Chapter 2B
Compression check . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 2B
Crankshaft rear oil seal - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder head - dismantling and inspection . . . . . . . See Chapter 2B
Drivebelt check, adjustment and renewal . . . . . . . . See Chapter 1
Engine - removal and refitting . . . . . . . . . . . . . . . . . See Chapter 2B
Engine mountings - check and renewal . . . . . . . . . . . . . . . . . . . . . . 17
Engine oil and filter change . . . . . . . . . . . . . . . . . . . See Chapter 1
Engine overhaul - general information . . . . . . . . . . . See Chapter 2B
Exhaust manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . 6
Flywheel/driveplate - removal and refitting . . . . . . . . . . . . . . . . . . . 15
Front oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intake manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 5Oil pump - removal, inspection and refitting . . . . . . . . . . . . . . . . . . 14
Repair operations possible with the engine in the vehicle . . . . . . . . 2
Rocker arm and shaft assembly - dismantling, inspection
and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 2B
Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Timing belt and sprockets - removal, inspection and refitting . . . . . 10
Timing belt covers - removal and refitting . . . . . . . . . . . . . . . . . . . . . 9
Timing chain and sprockets - removal, inspection and refitting . . . . 8
Timing chain covers - removal and refitting . . . . . . . . . . . . . . . . . . . 7
Top Dead Centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . . 3
Valve clearance check and adjustment . . . . . . . . . . . See Chapter 1
Valve cover - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves - servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 2B
2A•1
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty
Specifications Contents

Torque wrench settingsNm
Timing chain tensioner plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Timing belt tensioner bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Camshaft sprocket-to-camshaft bolt
M10 and M30 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
M20 and M40 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Flange to camshaft (M30 engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Timing chain or belt covers-to-engine
M6 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
M10 (bolt size) bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Crankshaft pulley bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Crankshaft hub bolt or nut
M10 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
M20 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
M30 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
M40 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
Cylinder head bolts*
M10 four-cylinder engine
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Stage 2 (wait 15 minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle-tighten an additional 33°
Stage 3 (engine at normal operating temperature) . . . . . . . . . . . . . Angle-tighten an additional 25°
M20 six-cylinder engine with hex-head bolts
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Stage 2 (wait 15 minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Stage 3 (engine at normal operating temperature) . . . . . . . . . . . . . Angle-tighten an additional 25°
M20 six-cylinder engine with Torx-head bolts
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle-tighten an additional 90°
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle-tighten an additional 90°
M30 six-cylinder engine (up to and including 1987 model year)
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Stage 2 (wait 15 minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle-tighten an additional 33°
Stage 3 (engine at normal operating temperature) . . . . . . . . . . . . . Angle-tighten an additional 33°
M30 six-cylinder engine (from 1988 model year)
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Stage 2 (wait 20 minutes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Stage 3 (engine at normal operating temperature) . . . . . . . . . . . . . Angle-tighten an additional 35°
M40 four-cylinder engine
Stage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Stage 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle-tighten an additional 90°
Stage 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Angle-tighten an additional 90°
Intake manifold-to-cylinder head bolts
M8 bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
M7 bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
M6 bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exhaust manifold-to-cylinder head nuts
M6 nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
M7 nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Flywheel/driveplate bolts
Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Intermediate shaft sprocket bolt (M20 engines) . . . . . . . . . . . . . . . . . . . 60
Sump-to-block bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 11
Oil pump bolts (except M40 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Oil pump sprocket bolts (M10 and M30 engines) . . . . . . . . . . . . . . . . . 10
Oil pump cover plate-to-engine front end cover (M40 engines) . . . . . . . 9
Front end cover-to-engine bolts (M20 and M40 engines)
M6 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Crankshaft rear oil seal retainer-to-block bolts
M6 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
M8 bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
* BMW recommend that the cylinder head bolts are renewed as a matter of course.
2A•2 In-car engine repair procedures