1993 BMW M3 ind

Brake
rotor,
removing
and
installing

Brake
rotors
shouldalways
be
replaced
in
pairs
.

Fig
.
9
.



Brake
rotor
mounting
screw
(arrow)
.

3
.
Inspect
rotor
for
excessive
grooving,
cracks,
and
warp-

ing
.
Check
rotor
thickness
.
See
Table
b
.

4
.
Installation
is
reverse
of
removal
.

"
Clean
rotor
with
brakecleaner
before
installing
.

"
If
brake
fluid
hose
veas
removed
or
loosened,
brake

systemmustbe
bled
as
described
aboveunder

Bleeding
Brakes
.

BRAKES
340-
7

5
.
Once
brake
assembly
is
instalind,
depress
brakepedal

several
times
to
adjust
caliper
and
pads
.

"
Pedal
should
feel
firm
and
be
at
proper
height
.

"
Check
fluid
leve¡
.
Top
up
if
necessary
.

NOTE-

M3
models
use
directional
brake
rotors
and
mustbe
in-



NOTE-

stalled
on
the
proper
side
.
Part
numbes
are
cast
finto



When
installing
new
rear
brake
rotors,
the
parking

therotors
.
A
part
that
ends
in
an
odd
number
is
a
left



brakeshouldbe
adjusted
.
See
Parking
Brake
.

rotor
.
One
that
ends
in
an
even
number
is
a
right
rotor
.

1.
Remove
caliper
as
described-above
and
hang
from



Tightening
Torques
chassis
using
stiff
wire
.



"
Brake
rotor
to
wheel
hub
..........
16
Nm
(12
ft-Ib)

"
Front
brake
caliper
to
steering
arm
...
110
Nm
(81
ft-Ib)

NOTE-



"
Rear
brake
caliper
to
traíling
arm
....
67
Nm
(50
ft-Ib)

Do
notloosen
caliper
brake
hose
.



"
Road
wheel
to
hub



...
..
.
100
±
10
Nm
(74
t
7
ft-Ib)

2
.
Remove
mountingscrew
holding
rotor
to
wheel
hub
.



,

See
Fig
.
9
.



Table
b
.
Brake
Rotor
Reconditioning
Specificati*M`

Front
Rear

Vented
rotor
wear
limit
(min
.
thickness)



20
.4
mm
(0
.803
in.)

Solid
rotor
wear
limit
(min
.
thickness)



8
.4
mm
(0.331
in
.)

M3
models
wear
limit
(min
.
thickness)



26
.4mm
(0
.977
in
.)



18
.4
mm
(0
.723
in
.)

Axial
runout
(max
.)
rotor
removed



0
.05
mm
(0
.002
in
.)



0
.05
mm
(0
.002
in
.)
rotor
installed



0
.20
mm
(0
.008
in
.)



0
.20
mm
(0
.008
in
.)

CAUTION-

M3
brake
rotors
must
not
be
machined
.

MASTER
CYLINDER

The
brake
master
cylinder
is
mounted
to
the
front
of
the
vac-

uum
booster
on
the
driver
side
bulkhead
.

Master
cylinder,
removing
and
installing

1
.
Using
a
clean
syringe,
empty
brake
fluid
reservoir
.

WARNING
-

Brake
fluid
is
highly
corrosive
and
dangerous
to
the

environment
.
Dispose
of
it
properly
.

NOTE-

On
original
equipment
rotors,
the
mínimum
allowable



2
.
Disconnect
brake
fluid
leve¡
sender
connector
from
fluid

thickness
is
stamped
on
the
rotor
hub
.
Measure
the
rotor



reservoi
r
cap
.

brakingsurface
with
a
micrometer
at
eight
to
ten
different

points
and
use
the
smallest
measurement
recorded
.



3
.
Disconnect
brake
fluid
lines
frommaster
cylinder
.
See

Fig
.
10
.
Disconnect
hydraulic
clutch
system
supply
line
.

4
.
Unscrew
mounting
nuts
and
remove
master
cylinder

from
brake
booster
.

5
.
Make
sure
all
nuts,
fluid
couplings,
thread
bores,
and

mating
surfaces
are
clean
.

MASTER
CYLINDER

340-
8
BRAKES

Fig
.
10
.
Brake
fluid
linesat
master
cylinder
(arrows)
.

6
.
If
fluid
reservoir
was
removed,
install
it
carefully
using
new
sealing
grommets
.

7
.
Mount
master
cylinder
to
brake
booster
using
a
new
0-
ring
and
new
self-locking
nuts
.

CAUTION-

Use
cave
not
to
over-torque
the
master
cylinder
mounting
nuts
.
This
could
damage
the
brake
booster
and
prevent
proper
vacuum
build-up
.

0012164

8
.
Connect
all
brake
fluid
lines
.
Connect
hydraulic
clutch
hose
to
brake
fluid
reservoir
.

9
.
Reconnect
fluid
leve¡
sender,
and
bleed
entire
brake
systemas
described
earlier
.

BRAKE
BOOSTER

BRAKE
BOOSTER

The
brake
booster
is
mounted
to
the
bulkhead
on
the
driver
sideofthe
engine
compartment,
directly
behind
the
brake
master
cylinder
.
See
Fig
.
11
.

0015225
Fig
.
11
.
Brake
booster
(arrow)
.
A
is
vacuum
hose
from
intake
mani-
fold
.
B
is
one-way
valve
.
Intake
manifold
vacuum
acts
ona
large
diaphragm
in
the
brake
booster
to
reducebrake
pedal
effort
.

Brake
booster,
removing
and
installing

1
.
Disconnect
negative
(-)
cable
from
battery
.

CAUTION-

Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
vi¡¡
.

Tightening
Torque

"
Brake
master
cylinder
to



2
.
Using
a
clean
syringe,
empty
brake
(luid
reservoir
.

brake
booster
.....
..
.
..
.........
26
Nm
(18
ft-Ib)



WARNING-
"
Brake
fluid
hose
to
caliper
....
17-19
Nm
(13-14
ft-Ib)



Brake
fluid
is
highly
corroslve
and
dangerous
to
the
environment
.
Dispose
of
it
properly
.

3
.
Remove
brake
fluid
level
sender
connector
from
reser-
voir
cap
.

4
.
Disconnectbrake
fluid
lines
from
master
cylinder
.
Plug
openings
.

5
.
Disconnect
engine
vacuum
hose
from
brake
booster
.

6
.
Disconnect
ABS
electrical
connectors
.
Label
and
then

disconnect
brake
lines
from
hydraulic
brake
unit
.
Plug

openíngs
.
See
Fig
.
12
.

~
~
A
1/
B
'1v
C
~
F

lu
11
-ri
J
.

0013244
A
.
Right
front



F



Front
from
master
cylinder
B
.
Leftfront



R
.
Rear
from
master
cylinder
C
.
Rear

Fig
.
12
.
Brake
fluid
linesat
ABS
hydraulic
unit
.

WARNING
-

"
On
cars
with
All
Season
Traction
(AST),
special
BMW
service
equipment
is
required
to
properly
bleed
the
Antilock
Brake
System
(ABS)
.
Removal
of
the
ABS
hydraulic
unit
is
not
recommended
un-
less
this
equipment
is
available
.
For
safetyrea-
sons,
the
brake
system
on
cars
with
ABS
must

not
be
bled
using
the
procedures
described
inthis
repair
group
.

"
Do
not
mix
up
the
fluid
fines
at
the
ABS
hydraulic
unit
Label
all
connections
before
disconnecting
.

7
.
Remove
ABS
hydraulic
unit
from
engine
compartment
.

8
.
Working
inside
car,
remove
panel(s)
frombeneath

steering
column
to
access
pedal
assembly
.
See513
In-

terior
Trim
.

12
.
Make
sure
al¡
nuts,
fluid
couplings,
thread
bores
and

mating
surfaces
are
clean
.

BRAKES
340-
9

0011261

Fig
.
13
.
Brake
pedal
clevispin
and
retaining
clip
(A)
.
Brake
booster
mounting
nuts
shown
at
arrows
.

13
.
If
necessary,
mount
master
cylinder
to
vacuum
booster

using
a
new
O-ríng
and
newself-locking
nuts
.

CAUTION-

Do
not
over-torque
the
master
cylinder
mounting
bolts
.
This
could
damage
the
brake
booster
and
prevent
proper
vacuum
build-up
.

14
.
Installation
is
reverse
of
Rmoval
.

"
Bleed
brakes
as
described
earlier
.

"
Check
and,
if
necessary,
adjust
brake
light
switch

above
brake
pedal
.

Tightening
Torques

"
Brakemaster
cylinder
to

brake
booster
...........
.
..
..
...
26
Nm
(18
ft-Ib)

"
Brake
booster
to
bulkhead
.
.
..
..
...
22
Nm
(16
ft-Ib)

"
Brake
fluidline
to
master
cylinder
or

ABS
hydraulic
unit
.......
.
..
17-19
Nm
(13-14
ft-lb)
9
.
Remove
clip
and
clevis
pin
from
brake
booster
pushrod

and
disconnect
it
from
brakepedal
.
Remove
brake

booster
mounting
nuts
.
See
Fig
.
13
.
NOTE-

10
.
Working
in
engine
compartment,
remove
brake
booster



When
replacing
the
brake
booster
one-way
valve
or
together
with
master
cylinder
.



vacuum
hose,
install
the
valve
so
that
the
molded
arrow

is
pointing
toward
the
intake
manifold
.
Use
new
hose

11
.
If
booster
or
master
cylinder
O-ring
is
being
replaced,



clamps
.

disconnect
master
cylinder
from
brake
booster
.

BRAKE
BOOSTER

400-2
BODY-GENERAL

4-door
Sedan

Coupe

-
saas3
.7""

351
/



37
.3
O



I
x
`-193



267

o
oa

'3281
model
"M3
model

Convertible

BODYASSEMBLY

55
ass
.e
iss
""
-
66
.9
-

Fig
.
2
.



E36
body
dimensíons
.

BODY
ASSEMBLY

29
.4

29
4

The
BMW
3
Series
chassis
is
a
unibodydesign
constructed
ofhigh
strength
steel
.
Attaching
parts,
suchas
the
front
fend-
ers,
rear
quarter
panels,
doors,
trunk
lid
and
hood
are
also
constructed
of
steel
.

706
.31108
.7"



I
38
.5
174
.5

174
.5

O



oo

196
.3/106
.7'
"



35_5



1.
.
55
.9,566
".

106
.3/196
.7""



i.
358
-1745-

55
9/56
3'/56
6"
-
J

0013099

Windows
bonded
flush
to
the
body
and
the
guided
flow
of
cooling
air
into
the
engine
compartment
provide
a
good
coeffi-
cient
of
drag(CD)
.
TheE36
cars
have
a
CD
of
approximately
0
.30for
the
sedan
and
coupe
models,
and
0
.35
for
the
con-
vertible
models
:

The
exterior
panels
are
corrosion-resistant
zinc
coated

steel
.
The
front
fenders
are
bolted
on
and
easily
replaceabie
.
The
body
styles
of
E36
cars
coveredby
this
manual
arethe



See410
Fenders,
Engine
Hood
.
4-door
sedan,
2-door
coupe
and
convertible
.
Body
dimen-
sions
vary
slightly
betweenmodels
.
See
Fig
.
2
.



The
front
and
rear
bumpers
use
an
aluminum
framework
with
an
overlaid
high-impact,
deformable
plastic
cover
.
This
Exterior
and
Aerodynamics



bumper
system
keeps
damage
to
a
minimum
in
head-on
colli-
sions
of
up
to
10
m
.p
.h
.
(15
km/h)
.
See
510
Exterior
Trim,
TheE36
can
be
immediatelyrecognized
asa
typical
BMW
.



Bumpers
.
With
its
traditionalstyling
features,
suchas
the
BMW
kidney
grille,
circular
headlights
behind
a
glass
cover
(for
reasons
of
streamliníng),
and
the
"kick"
in
the
rearmost
roof
pillar
(C-pil-
lar)
.

TheE36
convertible
is
an
all-season
vehicle
with
a
high
lev-
e¡offunctionality,
excellent
interior
comfort,
and
acoustic
re-

finement
.
Interior
materials
and
colors,
the
soft
top
and
the

light-alloy
wheelshave
been
carefully
matched
.

Various
versions
of
manual
and
automatic
soft
tops
have
been
used,
with
the
fully
automatic
convertible
roof
being
in-

stalled
beginning
in
the
1997
model
year
.

A
hard-top
in
body
color
with
heated
rear
window
is
avail-

ableas
an
option
for
the
cold
season
.

BODY-GENERAL
400-
3

Coupe
Models



The
convertible
body
structure
includes
many
passive
safe-

ty
refinements
over
its
fixed-top
counterparts
.
Some
of
the
en-

TheE36
coupe
is
similar
to
the4-door
sedan,
but
has
a



hancements
include
:

more
stretched
and
sleeker
appearance
.
Thus,
with
the
same

wheelbase
and
identicallength,
it
looks
different
but
still
famil-



"
More
rígíd
underbody
.

iar
.



"
Transverse
seat
members
.

"
Reinforced
windshield
frame
with
bonded
windshield,

The
2-door
variant
differs
from
the
4-door
sedan
by
a
3
.12



and
tubular
door
reinforcements
.

inch
(8
cm)
longer
front
end,
a
flatter
hood
line
with
air
slits,



"
Rollover
protection
system,
which
is
tripped
into
position

and
a
roof
almost
1
.2
inches
(3
cm)
shorter
.
Additional
differ-



in
a
fraction
of
second
.
This
is
available
as
optional

ences
include
wider
doors
with
frameless
Windows,
glass-



equipment
(standard
on
the
1998
328iC)
and
may
be
fit-

covered
door-posts
(B-pillars)
and
a
shorter
and
lower
lug-



ted
to
earlier
convertible
models
.
With
this
feature,
two

gage
compartment
lid
.



bars
fully
independent
of
each
other
come
up
behind

each
rear-seat
backrest
when
the
vehicle
is
in
danger
of

Convertible
Models



turning
over
.

A
convertible
body
normally
flexes
and
vibrates,
transfer-

ring
oscillations
to
the
luggage
compartment
.
In
the
E36
con-

vertible,
BMW
utilizes
a
special
battery
in
the
luggage
compartment,
in
conjunction
with
a
unique
battery
tray,
asa

vibration
dampening
system
to
counteract
thisoscillation
.

CAUTION
-

The
E36
convertible
requires
a
specialbattery
which
is
designed
for
constant
vibration
.

Information
for
the
convertible
top
and
its
related
mecha-

nisms
can
be
found
541
Convertible
Top
.

BODYASSEMBLY

400-
4
BODY-GENERAL

INTERIOR
EQUIPMENT

E36
interiors
have
a
unique
character,
with
a
combínation
of
sporty
features
and
innovative
design
.
Al¡
body
versions
were
made
in
a
wide
choice
of
interior
and
exterior
colors
.
New

colors
with
matching
leather
and/or
fabric
upholstery
were
in-
troduced
for
each
model
year,
including
light-alloy
wheels
in
new
designs
.

Driving
comfort
is
enhanced
by
power
steering,
tilt
steering
wheel
(optional),
height-adjustable
front
seats,
and
electrical-
ly
adjustable
and
heated
rear-view
mirrors
.
Inside
thecar
there
are
reading
lights
at
four
seating
positions
.

Seats
and
Seat
Belts



NOTE-

Theseat
base
usedon
cars
with
pyrotechnic
seatbelt

Anatom¡cal
ly-correct
seats
are
constructed
from
polyure-



tensioners
is
not
interchangeable
with
the
earlier
seat

thane
foam
containing
areas
or
"zones"
of
different
firmness
.



base
.

The
seat
bases
have
steel
springs
for
added
support
and
strength
.
The
power
seats
are
provided
with
conveniently
lo-



Instruments
and
Controls
cated
switches
along
the
outside
edge
of
the
seat
.
Heated
seats
are
an
option
in
all
models
.
See
520
Seats
for
more
de-



Everything
in
the
interior
passenger
compartment
essential
tails
.



to
the
driver
is
logically
grouped
and
easy
to
reach
.
Al¡
instru-
ments
and
controls
havebeen
arranged
ergonomically
and
The
M3
sport
seat
is
shown
in
Fig
.
3
.



are
fully
integrated
into
the
overall
design
of
the
vehicle
.

Fig
.
3
.



M3
sport
seat
.

INTERIOR
EQUIPMENT

0013195

The
early
E36
cars
areequipped
with
a
single
(driver
side)
airbag
in
the
steering
wheel
.
Startingwith
the
1994
models,
a
dual
airbag
Supplemental
Restraint
System
has
been
stan-
dard
equipment
.
Side-impact
airbags
in
the
front
doors
are
op-
tional
in
1997
4-door
cars
and
standard
equipment
in
all
1998
models
.

Through
1996,
E36
seatbelts
were
equipped
with
BMW's
original-designspring
tensioners
.
In
1997,
the
seat
base
de-
sign
was
modified
to
accommodate
a
pyrotechnic
(explosive
charge)
seatbelt
tensioner
.
Both
types
of
tensioners
arede-
signed
to
automatically
tension
the
belts
by
about2
inches(55
mm)
in
the
event
of
a
collision
.

The
padded
dashboard
houses
the
instrument
cluster
and
the
ventilation
and
heating
system
.
The
instrument
cluster
uses
large
easy-to-read
analog
instruments
and
is
removable
as
a
unit
without
removing
the
dashboard
.
The
Service
Inter-
val
Indicator
(SII)
will
remind
the
driver
when
thecar
requires
service
.
See
620
Instruments
.

The
Multi-Information
Display
(MID)
unit
in
thecenter
of
the
dashboard
comes
in
a
variety
of
four
configurations,
the
most
advanced
being
the
On-Board
Computer
(OBC)
.
See
Fig
.
4
.

Al¡
versions
of
the
MID
have
a
clock
and
calendar
.
In
addi-
tion,
different
versions
areequipped
with
a
"check
control,"

display
for
fuel-economy
information
and
system
warnings
.
Consult
the
owner's
manual
for
fui¡
operating
instructions
.

Ambient
temperaturelclock

MÍM
Aa
.Mi}rm
-Mil"
IMua~naa~u~itacar
"
za
.~

Central
Body
Electronics

0013028

Fig
.
4
.



Different
versionsof
Multi-information
Display(MID)
installed
in
E36
cars
.

The
E36
cars
are
equipped
with
a
sophisticated
centralized

body
electric/electronics
plan
.
The
system
is
self-diagnostic

and
incorporates
many
functions
into
a
single
control
module
.

The
consolidation
of
several
systems
into
a
single
control

module
minimizes
power
requirements
and
the
incorporation

of
the
diagnostic
link
results
in
more
efficient
and
accurate

troubleshooting
.

Self-diagnostic
codes
are
accessible
electronically
through

the
data-link
connector
in
the
engine
compartment
.
See610

Electrical
Component
Locations
.

BODY-GENERAL
400-
5

Two
versions
of
central
body
electronics
are
used
depend-

ing
on
model
year
.

1992
and
1993
models
are
equipped
with
a
central
locking

module
(ZVM)
which
incorporates
control
of
the
following
sys-

tems
:

"Interiorlighting
"
Central
locking
with
double
lock
feature

"
Output
relays
for
powerwindows
and
sunroof

"
Electronic
power
protection

E36
cars
since
the
1994
model
year
are
equipped
with
ZKE

IV
.
This
is
an
electronic
comfort
and
convenience
system
that

includes
the
following
additional
features
:

"
One
touch
up/down
power
window
operation

"
Power
window
and
sunroof
closure
from
driver
or
pas-

sengerdoor
lock

"
Vehicle
locking
or
unlocking
from
the
trunk
lock
.

Other
features
of
the
system
are
discussed
in
515
Central

Locking
and
Anti-Theft
.

Electronic
Immobilization
System

Beginning
in
model
year
1994,
all
E36
vehicles
incorporate

adriveaway
protection
system
regardless
of
whether
the
vehi-

cle
is
equipped
with
a
BMW
Alarm
System
or
an
On-Board

computer
.
Two
types
of
factory
systems
were
installed,
de-
pending
on
vehicle
production
date
.

On
the
early
system
(model
year
1994
up
to
January
1995),

the
ignition
and
fuel
injection
functions
are
disabled
whenever

the
vehicle
is
locked
in
the
double
lock
mode
.
This
is
referred

lo
as
EWS
or
EWS
I
.

Beginning
in
January
1995,
the
driveaway
protection
sys-

tem
was
upgraded
to
a
more
sophisticated
system,
called

EWS
II
.
This
system
uses
a
wireless
communication
link
be-

tween
a
transponder
chip
in
the
ignition
keyand
the
ring
an-

tenna
surrounding
the
ignition
switch
.
The
EWS
II
control

module
blocksthe
starting
of
the
vehicle
unlessthe
correct

coded
ignition
key
is
used
.

For
further
information
about
drive
away
protection
sys-

tems,
see
515
Central
Locking
and
Anti-Theft
.

INTERIOR
EQUIPMENT

ENGINE
HOOD

Hood,
raising
to
service
position

CA
UTION-

Do
not
switch
on
the
windshield
wipers
wlth
the
engine
hood
raised
.
As
a
precaution,
remove
the
wiper
motor
fuse
.
See
610
Electrical
Compo-
nent
Locations
.

1
.
4-door
models
:
Open
hood
fully
.
Remove
bolt
from

hood
hinge
behind
hood
supports
(left
and
right)
.
Raise
hood
to
service
position
.
See
Fig
.
5
.

2
.
2-door
models
:
Open
hood
fully
.

Fig
.
5
.



Hood
support
bracket
boltto
be
removed
(A)
on
4-door
cars
.

Remove
bolts
at
left
and
right
hinges
.
Swing
bracket
in
direc-
tion
of
arrow
to
raise
hood
into
service
position
.

"
Remove
ground
cable
atright
hood
hinge
.

"
Whilean
assistant
supports
hood,
detach
both
hood

supportsfrom
hood
.

"
Remove
detent
screws
at
back
of
hood
hinges
.
See

Fig
.
6
.
"
Lift
hood
while
pulling
hinge
forward
.
Support
hood
at

higher
position
.

3
.
When
service
work
is
complete,
return
hood
to
lower

position
and
instaf
screws
or
bolts
.

FENDERS,
ENGINE
HOOD



410-
3

Fig
.
6
.



Torx
screw
at
base
of
hood
hinge
(arrow)
.

Hood,
removing
and
installing

0013147

1
.
Raise
hood
.
Where
applicable,
partially
remove
hood

acoustic
insulation
to
access
rear
of
hood
.
See
Fig
.
7
.

Fig
.
7
.



Hood
insulation
retainer
being
pried
out

3
.
Detachgas-charged
hood
supportsfrom
hood
.

CAUTION
-

The
hood
is
heavy
.
Before
removing
the
hood
sup-
ports
or
hood
retainingbolts,
be
sure
to
have
an
assistant
help
support
the
hood
.

0013148

2
.
Disconnect
washer
fluid
hoses
from
washer
nozzles
.

Where
applicable,
disconnect
electrical
harness
con-

nectors
fromheated
nozzles
.

ENGINE
HOOD