
170-8
RADIATOR
AND
COOLING
SYSTEM
Electric
cooling
fan,
replacing
On
late
4-cylinder
models
(M44
engine)
with
manual
trans-
mission,
the
primary
cooling
fan
is
electrically
operated
and
is
mounted
on
the
engine
side
of
the
radiator
.
1
.
If
necessary,
remove
cover
from
top
of
radiator
.
See
Fig
.
10
.
0012505
Fig
.
10
.
Air
cover
in
back
of
radiator
.
Unclip
cover
from
fan
shroud
af-
ter
removing
mounting
screws
.
2
.
Disconnect
fan
harness
connector
at
bottom
left
of
ra-
diator
.
3
.
Remove
fan
shroud
mountingscrews
at
left
and
right
side
of
radiator
.
Lift
fan
assembly
straight
up
and
offra-
diator
.
4
.
Installation
is
reverse
of
removal
.
Be
sure
to
align
side
tabs
on
fan
housíng
with
retaining
tabs
on
radiator
when
reinstalling
fan
.
Auxiliary
cooling
fan,
replacing
The
auxiliary
electric
cooling
fan
is
mounted
behind
the
front
bumper,
in
front
of
the
A/C
condenser
.
There
aretwo
ver-
sions
of
auxiliary
fans
installed,
depending
on
model
and
en-
gine
installed
.
TType
1
(u
p
to
9192)
1
.
Remove
front
radiator
air
shroud
.
See
Fig
.
11
.
2
.
Remove
fan
mountingscrews
.
See
Fig
.
12
.
3
.
Tilt
fan
forward
.
Disconnect
electrical
harness
connec-
tor
before
lifting
fan
up
.
COOLING
SYSTEM
SERVICE
Fig
.
11
.
Front
radiator
air
shroud
fasteners
(arrows)
.
Fig
.
12
.
Version
1
auxiliary
fan
mountingscrews
(arrows)
.
NOTE
-
If
necessary,
remove
front
bumper
or
lowerengine
cov-
erto
access
electrical
harnessconnector
.
4
.
Installation
is
reverse
of
removal
.
l)
Type
2
(from
9192)
2
.
Remove
fan
mounting
screws
.
See
Fig
.
13
.
0013137
1.
Remove
front
bumper
and
radiator
grilles
.
See
510
Ex-
terior
Trim,
Bumpers
.
3
.
Angle
fan
up
and
forward,
disconnecting
electrical
har-
nessconnectorbehind
it
.
Remove
it
through
bumper
opening
.

Fig
.
13
.
Version
2
auxiliary
fan
mounting
screws
(arrows)
.
Front
bumper
hasbeen
removed
.
4
.
Installation
is
reverse
of
removal
.
Thermostat,
replacing
0013146
The
coolant
thermostat
is
instalied
in
a
housing
at
the
front
of
the
cylinder
head
.
See
Fig
.
14
.
Fig
.
14
.
Coolantthermostat
and
housíng
.
NOTE-
On
M44
engines,
the
thermostat
is
integrated
into
the
thermostat
housíng
.
If
the
thermostat
requiresreplace-
ment,
the
complete
thermostathousing
mustbe
replaced
.
RADIATOR
AND
COOLING
SYSTEM
170-
9
WARNING
-
Allow
the
cooling
system
to
cool
before
opening
ordraining
the
system
.
2
.
Remove
belt-driven
cooling
fan
and
fan
shroudas
de-
scribed
earlier
.
3
.
On
M52/S52US
engines
:
Unclip
wiring
duct
retaining
clips
and
remove
duct
from
above
thermostat
housing
.
Also
remove
engine
front
lifting
bracket
.
4
.
Remove
thermostat
housing
from
front
of
engine
.
See
Fig
.
15
.
Fig
.
15
.
Thermostat
housíng
shown
removed
(6-cylinder
engine)
.
NOTE-
Some
thermostats
have
a
direction
arrowor
venthole
near
the
edge
.
Install
the
thermostat
so
that
either
the
arrow
or
hole
are
at
thetop
.
CAUTION
-
Be
sure
to
reconnect
ground
wire(s)
at
thermostat
housing
mounting
bolt,
where
applicable
.
5
.
Remove
thermostat
.
Note
thermostat
direction
and
ori-
entation
before
removing
.
6
.
Insta¡¡
new
thermostat
and/or
thermostat
housing
using
new
O-ring
and
gasket(s)
as
necessary
.
oo131ss
7
.
Installation
is
reverseof
removal
.
Fill
system
with
cool-
ant
as
described
under
Coolant,draining
and
filling
.
Tightening
Torques
1
.
Drain
radiator
as
described
above
under
Coolant,
"
Thermostat
housing
cover
draining
and
filling
.
to
housing
orcoolant
pump
..
..
....
10
Nm
(89
in-lb)
"
Engine
lifting
bracket
bolt
to
thermostat
housing
(M52/S52US
engine)(M8)
....
..
...
22
Nm
(17
ft-Ib)
COOLING
SYSTEM
SERVICE

170-10
RADIATOR
AND
COOLING
SYSTEM
Coolant
pump,
replacing
The
engine
coolant
pump
is
mounted
in
the
frontof
the
en-
gine
on
the
timing
cover
.
See
Fig
.
16
.
Fig
.
16
.
Coolant
pump
mounted
on
timing
cover
.
NOTE-
Onlyreplacement
coolant
pumps
with
metal
¡mpellers
should
be
installed
.
Pumps
with
plastic
impellers
should
not
be
used
.
1.
Drain
cooling
system
as
described
earlier
.
0013197
WARNING
-
Allow
cool¡ng
system
to
cool
before
open¡ngor
drain¡ng
system
.
2
.
Remove
primary
cooling
fan
shroud
and
cooling
fan
(belt-driven
or
electric)
as
described
earlier
.
Fig
.
17
.
Engine
drive
belt
tensioner
being
released
on
M44
engine
.
Pry
off
tensioner
cover
and
then
lever
tensioner
in
counterciock-
wise
direction
(as
facing
engine)
and
slip
belt
off
pulleys
.
Fig
.
18
.
Drive
belt
tensioner
being
released
on
M52
engine
.
Pry
off
3
.
Disconnect
hoses
from
thermostat
housing
.
Unbolt
tensioner
cover
and
then
lever
tensioner
clockwise
(as
facing
thermostat
housing
from
front
of
cylinder
head
.
engine)torelease
belt
tension
.
4
.
Remove
coolant
pump
drive
belt
.
See
Fig
.
17
or
Fig
.
18
.
NOTE-
-
Mark
direction
of
drive
belt
rotation
if
reusing
belt
.
"
The
6-cylinder
coolant
pump
¡s
mounted
on
studs
and
retained
by
nuts
.
"
Severa¡
drive
belt
and
tensioner
configurations
havebeenused
in
E36
models
.
Refer
to
020
Maintenance
Program
and
640
Heating
and
Air
Conditioning
.
5
.
Remove
coolant
pump
pulley
from
pump
.
6
.
Remove
mounting
fasteners
from
pump
.
COOLING
SYSTEM
SERVICE
NOTE-
"
The
4-cylinder
coolant
pump
¡s
mounted
us¡ng
two
dif-
terent
length
bolts
.
Note
where
thelonger
bolt
fits
dur-
ing
disassembly
.
0011989
7
.
Insert
twoscrews
(M6)
in
tapped
bores
and
tighten
uni-
formly
until
pump
is
free
from
timing
chain
cover
.
See
Fig
.
19
.

Fig
.
19
.
Coolant
pump
being
removed
.
Thread
two
M6
bolts
(arrows)
in
evenly
to
withdraw
pump
.
(Thermostat
and
hoseshavebeen
removed
tor
visual
access
.)
8
.
Installation
is
reverse
of
removal
.
"
Be
sure
to
replace
O-ring
and
gaskets
.
"
Coat
O-ring
with
lubricant
during
installation
.
Tightening
Torque
"
Coolant
pump
to
timing
chaincover
M6
...
.
...................
..
.
.
10
Nm
(89
in-lb)
M8
.
..
.
....................
.
.
.
22
Nm
(17
ft-Ib)
"
Coolant
pump
pulley
to
coolant
pump
.................
10
Nm
(89
in-lb)
RADIATOR
SERVICE
Radiator,
removing
and
installing
1
.
Drain
radiator
as
described
earlier
.
WARNING
-
Allow
cooling
system
to
cool
before
opening
ordraining
system
.
2
.
Remove
primary
cooling
fan
(belt-driven
or
electric)
as
described
earlier
.
3
.
Disconnect
coolingfan
and
leve¡
sensor
harness
con-
nectors
from
bottom
of
radiator,
where
applicable
4
.
Disconnect
harness
connector
from
auxiliary
fandual
temperature
switch
.
See
Fig
.
20
.
5
.
Disconnect
all
coolant
hoses
from
radiator
.
RADIATOR
AND
COOLING
SYSTEM
170-11
0012500
Fig
.
20
.
Cooling
fan
dual
temperatura
switch
(arrow)
on
right
sido
of
radiator
.
6
.
Where
applicable,
disconnectautomatic
transmission
fluid
(ATF)
cooler
lines
from
radiator
.
See
Fig
.
21
.
Fig
.
21
.
Automatic
transmission
fluid
(ATF)
linos
at
radiator
.
7
.
Carefully
pryout
radiator
retaining
clips
from
top
of
ra-
diator
.
See
Fig
.
22
.
8
.
Pul¡
radiator
up
and
out
of
car
.
NOTE-
The
radiator
rests
ontwo
rubber
mounts
.
Check
that
the
mounts
do
not
stick
to
the
bottomof
the
radiator
.
RADIATOR
SERVICE

170-12
RADIATOR
AND
COOLING
SYSTEM
Fig
.
22
.
Radiator
retaining
clip
being
removed
.
Push
down
and
pulí
screwdriver
forward
to
release
clip
.
9
.
Installation
is
reverse
of
removal
.
"
Fill
radiator
and
cooling
system
as
described
under
Coolant,
draining
and
filling
.
"
Check
ATF
leve¡
and,
if
necessary,
top
up
.
See
240
Au-
tomatic
Transmission
.
RADIATORSERVICE

GENERAL
.
.
.......
.
......
.
...
.
.
.
.
.
...
180-1
Exhaust
system,
removing
and
installing
.
...
.180-3
EXHAUST
SYSTEM
REPLACEMENT
.
...
180-1
Exhaust
manifolds,
removing
and
installing
.
.
.180-5
GENERAL
The
exhaust
system
is
designed
to
be
maintenance
free,
al-
though
regular
inspection
is
warranted
due
to
the
harsh
oper-
atingconditions
.
Under
normal
conditions,
the
catalytic
converter
does
not
require
replacement
unless
it
is
damaged
.
On
1996
and
later
cars,
a
pre-
and
post-catalytic
converter
oxygen
sensor
is
used
at
each
catalytic
converter
.
Be
sure
to
take
care
when
removingthe
system
not
to
damage
the
sen-
EXHAUST
SYSTEMREPLACEMENT
sors
.
See
130
Fuel
Injection
for
information
on
testing
oxygen
sensors
.
NOTE-
OnM52
engines,
two
resonator
pípes
(short
and
long)
are
incorporated
into
the
rear
muffler
assembly
.
See
Fíg
.
1
.
An
exhaust
flap
is
integrated
into
the
outlet
side
of
the
short
pipe
.
The
flap
is
operated
by
a
vacuum
ac-
tuator
via
the
Siemens
MS
41
.1
engine
control
mod-
ule)
.
The
flap
is
closed
at
engine
speeds
below
2,500
rpm
.
This
allows
exhaust
gasses
to
flow
through
the
long
resonator
pipe
and
reduce
noise
.
Above
2,500rpm,
the
exhaust
flap
is
open
(no
vacuum
applied
to
the
actuator)
and
allows
exhaust
gasses
to
flow
through
the
short
pipe
for
maximum
performance
.
180
Exhaust
System
0013101
Fig
.
1
.
Rear
muffler
(active
silencer
usedon
M52
engines)
.
Vacuum
operated
flap
(A)
changesbetween
short
and
long
pipes,
de-
pending
on
engine
speed
.
EXHAUST
SYSTEM
180-1
WARNING
-
Exhaust
gases
are
colorless,
odorless,
and
very
toxic
.
Run
the
engine
only
ín
a
well-ventilated
area
.
Immediately
repair
any
leaks
in
the
exhaust
system
or
structural
damage
to
the
car
body
that
might
al-
lowexhaust
gases
to
enter
the
passenger
compart-
ment
.
Exhaustsystem
components
are
detailed
in
Fig
.
2
through
Fig
.
4
.
New
fasteners,
clamps,rubber
mounts,
and
gaskets
should
be
used
when
replacing
exhaust
components
.
A
liberal
appli-
cationof
penetrating
oil
to
the
exhaustsystem
nuts
and
bolts
in
advance
may
make
removal
easier
.
WARNING
-
"
The
exhaust
system
and
catalytic
converter
op-
erate
at
high
temperatures
.
Allow
components
to
cool
before
servicing
.
Wear
protectíve
clothíng
to
prevent
bums
.
Do
not
use
flammable
chemicals
near
a
hot
catalytic
converter
.
"
Old,
corroded
exhaust
system
components
crumble
easíly
and
often
have
exposed
sharp
edges
.
To
avoid
injury,
wear
eye
protection
and
heavy
gloves
when
working
with
old
exhaust
parts
.
EXHAUST
SYSTEM
REPLACEMENT
T

200-2
TRANSMISSION-GENERAL
Transmission
ID
Codes
On
both
manual
and
automatic
transmissions,
the
code
let-
ter
and
transmission
type
numbers
should
be
located
onan
ID
plate
attached
to
the
síde
of
thetransmission
.
Do
not
rely
on
numbers
cast
on
the
transmission
case
for
identification
.
In
addition,
thetransmission
lubricant
varies
between
trans-
missions
and
model
years
.
Fluid
application
information
should
be
clearly
marked
on
a
label
on
thetransmission
.
On
manual
transmissions,
either
ATF
(orange
label
reads
ATF-Oil!)
or
a
special
BMW
lubricant
(yellow
label
reads
MTF-
LT
1)
are
used
.
See
230Manual
Transmission
.
Automatic
transmissions
are
filled
with
either
Dexron
III
ATF
(black
trans
.
type
plate
reads
ATF-Oil!),
a
special
ffe-
time
oil
(green
trans
.
type
plate
reading
Life-Time
ó1)
.
See
240AutomaticTransmission
.
GENERAL
CAUTION-
lf
in
doubtas
to
the
typeof
fluid
installed
in
a
par-
ticular
transmission,
consult
and
authorized
BMW
dealer
service
department
for
the
latest
in
operat-
ing
fluids
.
Fig
.
2
.
Typical
location
of
IDpíate
on
automatic
transmission
housing
(arrow)
.
A4S
310R
(THM-R1)

210-2
CLUTCH
Clutch
hydraulic
system,
bleeding
and
flushing
If
the
clutch/brake
fluid
is
murky
or
muddy,
or
has
not
been
changed
within
the
last
two
years,
the
system
should
be
flushed
.
Flushing
the
old
fluid
from
the
clutch
lines
is
done
us-
ing
a
brake
system
pressure
bleeder
.
1
.
Remove
brake
fluíd
reservoir
cap
.
Usinga
clean
sy-
ringe,
remove
brake
fluid
from
reservoir
.
Refill
reservoir
with
clean
fluid
.
2
.
Attach
pressure
brake
bleeder
to
fluid
reservoír
.
CA
UTION-
Do
not
exceed
2
bar
(29
psi)
pressure
at
the
fluid
reservoir
when
bleeding
or
flushing
the
hydraulic
system
.
3
.
Connect
a
length
of
hose
from
clutch
slave
cylinder
bleeder
valve
lo
a
container
.
See
Fig
.
2
.
0012003
Fig
.
2
.
Clutch
slave
cylinder
bleeder
valve
on
left
side
of
transmission
(arrow)
.
4
.
Open
bleeder
valve
and
allow
brake
fluid
to
expel
until
clean
fluid
comes
out
free
of
air
bubbles
.
5
.
Close
bleeder
valve
and
disconnect
pressure
bleeding
equipment
from
fluid
reservoir
.
Hose
on
bleeder
valve
remainsconnected
.
6
.
Slowly
operate
clutch
pedal
about10
times
.
Fill
reser-
voir
with
clean
fluid
asnecessary
.
7
.
Unbolt
slavecylinder
from
transmission
.
8
.
Position
slave
cylinder
so
that
bleeder
valve
is
facing
up
(highest
point)
.
CLUTCH
HYDRAULICS
9
.
Open
bleeder
valve
and
slowly
push
slave
cylinder
pushrod
al¡
the
way
in
.
Close
bleeder
valve
and
slowly
release
pushrod
.
Repeat
procedure
until
fluid
runs
out
clear
and
without
bubbles
.
10
.
Disconnect
bleeder
hose
.
Instan
slavecylinder
lo
trans-
mission
.
Add
cleanbrake
fluid
to
reservoir
as
neces-
sary
.
Check
clutch
operation
.
Tightening
Torques
"
Clutch
slave
cylinder
to
transmission
................
..
22
Nm
(17
ft
lb)
Clutch
master
cylinder,
replacing
The
clutch
master
cylinder
is
mounted
to
the
pedal
assem-
bly,
directly
above
the
clutch
pedal
.
1
.
Disconnect
negative
(-)
cable
from
battery
.
CAUTION-
Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautionsgiven
at
the
front
of
this
manual
on
page
viii
.
2
.
Remove
brake
fluid
reservoir
cap
.
Usinga
clean
sy-
ringe,
remove
brake
fluid
from
reservoir
.
CA
UTION-
Brake
fluid
is
poisonous,
highly
corrosive
and
dan-gerous
to
the
environment
.
Wear
safety
glasses
and
rubbergloves
when
working
with
brake
fluid
.
Do
notsiphonbrake
fluid
with
your
mouth
.
Imme-
diately
clean
away
any
fluid
spilled
on
painted
sur-
faces
and
wash
with
water,
asbrake
fluid
will
remove
point
.
3
.
Disconnect
fluid
supply
hose
from
master
cylinder
.
Placea
pan
under
hose
to
catch
any
excess
fluid
.
4
.
Working
in
engine
compartment,
disconnect
fluid
line
fitting
frommaster
cylinder
.
5
.
Working
in
passenger
compartment,
remove
lower
in-
strument
panel
trim
above
pedal
cluster
.
6
.
Disconnect
clutch
pedal
from
clutch
master
cylinder
push
rod
by
removing
clevis
pin
locking
clip
and
slide
out
clevis
pin
.
7
.
Remove
master
cylinder
mounting
bolts
.
See
Fig
.
3
.
8
.
Installation
is
reverse
of
removal
.
Fill
fluid
reservoir
with
clean
fluid
.
Bleed
clutch
hydraulics
as
described
earlier
.
Connect
negative
cable
to
battery
last
.