1994 BMW 325i auto gear shift

General
Data
and



010
FundamentalsfortheDo-lt-YourselfOwner

Maintenance



020
Maintenance
Program

Engine

Transmission

Suspension,

Steering
and

Brakes

4
Body

100
Engine-General

110



Engine
Removal
and
Installation
113



Cylinder
Head
Removal
and
Installation
116



Cylinder
Head
and
Valvetrain
117



Camshaft
Timing
Chain

119



Lubrication
System

200
Transmission-General
210
Clutch
230
Manual
Transmission

510



Exterior
Trim,
Bumpers



520



Seats

Bo
y
Equipment



512
DoorWTdws



540



nr
t

513



InteriorTrim



541



Convertible
Top

515



Central
Locking
and
Anti-Theft

600



Electrical
System-General



620



Instruments

Electrical
S



stem
610
Electrical
Component
Locations



630
Exterior
Lighting

611



Wipers
and
Washers



640



Heating
and
Air
Conditioning

6



612



Switches
and
Electrical
Accessories



650



Radio

Equipment
and



720
SeatBelts

Accessories



721
Airbag
System
(SRS)

Electrical
Wiring

Diagrams

Foreword
.
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.
...
.
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.
.
.
................
.
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.....
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......
.
................
.
.
.
.....
v

Warnings
and
Cautions
.....
.
...
.
.
.
.
.
..........
.
...
.
.
.
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......
.
.........
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...
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......
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............
.
.
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.vii

Index
..............
.
.
.
.....
.
............
.
...
.
.
.
.
.
........
.
...
.
.
.
.
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.......
.
......
.
...
.
.
.
.
.
.
.
........
.
.
.
..
back
of
book

300



Suspension,
Steering
and



330



RearSuspension

Brakes-General



331



Final
Drive

310



Front
Suspension



340



Brakes

320



Steering
and
Wheel
Alignment

400
Body-General



411
Doors

410



Fenders,
Engine
Hood



412



Trunk
Lid

120



Ignition
System
121



Battery,Starter,
Alternator
130



Fue¡
Injection
160



Fuel
Tank
and
Fuel
Pump
170



Radiator
and
Cooling
System180



Exhaust
System

240



Automatic
Transmission
250



Gearshift
Linkage

260
Driveshaft

Table
i
.
ECM
Pin
Assignment-Bosch
DME
M3
.1

Pin



Signal



Component/function



2

ignal

FUEL
INJECTION



130-
3
1

45
vacant
-

46
vacant
-



-

47
vacant
-



-

48



output



A/C
compressor
control



A/C
compressor
disabled
via
compressor
control
relay

49
vacant
-



-

50



output



Ignition
control
(terminal
1),cyl
.
n
o
.
4



Primary
signal,
ignition
coil
cyl
.
n
o
.
4

51



output



Ignition
control
(terminal
1),cyl
.
n
o
.
6



Primary
signal,
ignition
coil
cyl
.
no
.
6

52



output



Ignition
control
(terminal
1),cyl
.
n
o
.
5



Primary
signal,
ignitioncoil
cyl
.
no
.
5

53
vacant



-

54



input



Power
supply



Battery
voltage
(+)
from
main
relay
terminal
87
55



ground



Ground



Ground
for
ignition
control

56



input



Power
supply
(terminal
15)



Batteryvoltage
(+)
with
key
on
or
engine
running

57
vacant
-



-

58
vacant
-



-

59



output



Throttleposition
sensor



Throttleposition
sensorsupply
voltage
(5
VDC)

60



input



Data
link
connector



Programming
voltage

61
vacant
-



-

62
vacant
-



-

63
vacant
-



-

64



input



Ignition
timing
intervention



from
A/T
control
module
(only
active
during
gearshift)

65



input



Automatic
transmission
(A/T)
range
switch



Transmission
park
or
neutral
signal

66
vacant
-



-

67



input



Engine
speed/crankshaft
position
sensor



Crankshaft
position/rpm
(voltage
(VAC)
between
pins
67
and
68)

68



input



Engine
speed/crankshaft
position
sensor



Crankshaft
position/rpm
(voltage
(VAC)
between
pins
67
and
68)

69
vacant
-



-

70



input



Oxygen
sensor



Oxygen
sensor
signal
(0-1
VDC
fluctuating
with
engine
running)

71



ground



Oxygen
sensor



Oxygen
sensor
signal
ground

72
vacant
-



-

73



input



Road
speed



Road
speed
signal
from
instrument
cluster

74



output



Engine
speed
(TD)



Engine
speed
(TD)
signalto
instrument
cluster

75
vacant
-



-

76
vacant
-



-

77



input



Intakeair
temperature
(IAT)
sensor



Intake
air
temperature
(0-5
V,
temperaturedependent)

78



input



Engine
coolant
temperature
(ECT)
sensor



Engine
coolant
temperature
(0-5V,
temperature
dependent)

79
vacant
-



-

80
vacant
-



-

81



input



On-boardcomputer



Drive-away
protection
enable

82
vacant
-



-

83
vacant
-



-

84
vacant
-



-

85



input



A/C
pressure
switch



From
Integrated
climate
control
module
via
A/C
pressure
switch

86



input



A/C
compressor
on



From
Integrated
climate
control
module
87



input



Diagnostic
connector
(RxD)



Diagnostic
RxD
(receive)signal
to
pin
15
in
Data
link
connector

88



input/output



Diagnostic
connector
(TxD)



Diagnostic
TxD
(transmit)
signal
to
pin
20
in
Data
link
connector

ECM
PIN
ASSIGNMENTS

GENERAL
..
.
.
.
.
.
.
.
.
.
.
.
.
.
......
.
......
210-1



CLUTCH
MECHANICAL
.
.
.
.
.
...
.
.....
.
.
210-3

CLUTCH
HYDRAULICS
.
.
.
.............
210-1



Clutch,
removing
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
...
.
.
.
.
210-4

Clutch,inspecting
and
installing
.
.
.
.
.
.
.
.
.
.
.
.210-5Clutch
hydraulic
system,



Transmission
pilot
bearing,replacing
.
.
.
.
...
210-6
bleeding
and
flushing
.
.
.
.
.
.......
.
.....
210-2

Clutch
master
cylinder,
replacing
..
.
.
.
.
.
...
210-2



Table

Clutch
slave
cylinder,
replacing
...
.
.
.
.
.
.
.
.
210-3



a
.
Clutch
Disc
Diameter
.............
..
..
.
......
210-3

GENERAL



CLUTCH
HYDRAULICS

This
repair
group
covers
replacement
of
the
clutch
mechan-



The
Clutch
is
hydraulically
actuated
by
the
master
and
slave
¡cal
and
hydraulic
components
.
Special
tools
may
be
required



cylinders
.
Clutch
disc
wear
is
automatically
taken
upby
the
for
some
of
the
procedures
.
Read
the
procedure
through
be-



pushrod
travelof
the
slave
cylinder,
making
periodic
adjust-fore
beginning
a
job
.



ments
unnecessary
.

NOTE-

See200
Transmission-General
for
transmission
applicatíon
information
.

The
major
components
of
the
clutch
system
are
shown
in

Fig
.
1
.

Engine



Pressure
plate

flywheel,,
assembly

Clutch

Flywheel
bolt

Pressure
plate
release
lever



Release
lever

Fig
.
1
.



Clutch
assembly
and
hydraufcs
.

210
Clutch

Release
bearing

Pushrod

A
soft
or
spongy
feel
to
the
clutchpedal,
long
pedal
free-
play,
or
grinding
noises
from
thegears
while
shifting
can
all
in-
dicate
problems
with
the
Clutch
hydraulics
.
In
these
circum-
stances
it
is
best
to
start
with
a
clutch
fluid
flush,
followed,
if

necessary,
byreplacement
of
the
hydraulic
parts
.

From
brake
fluid
reservoir

CLUTCH
210-1

0

0

Transmission
inputshaft

Clutch
master
cylinder

Bulkhead

Slave
cylinder
6535

CLUTCH
HYDRAULICS

240-2



AUTOMATIC
TRANSMISSION

WARNING
-

If
the
appropriate
temperature
measuring
equip-
ment
is
not
available,
ATF
leve¡
checking
shouldbe
left
to
an
authorized
BMW
dealer
The
checking
pro-
cedure
should
be
done
on
a
lift
with
the
engine
run-
ning
in
neutral
.
In
addition,
the
transmission
fluid
temperature
must
be
maintained
within
a
narrow
range
duringthe
checking
procedure
.

1
.
Place
vehicle
on
a
lift
.

WARNING
-

To
lift
the
vehicle
safely,
see
010
Fundamentals
for
the
Do-it-Yourself
Owner
.

2
.
Warm
up
drivetrain
by
running
engine
until
ATF
reach-

es
specified
temperature
.
Apply
brake
and,
while
idling
engine,
shift
through
all
gears
severa¡
times
.
Turn
en-
gine
off
.

ATF
Level
Checking

"
Fluid
temperature
..
...........
30-55°C
(86-131°F)

3
.
Remove
ATF
fill
plug
.
Place
transmission
in
neutral
and



ATF,draining
and
filling
restart
engine
.
See
Fig
.
1
or
Fig
.
2
.

Fig
.
1
.



ATF
fill
plug
(A)
on
MS
270R/A4S310R
transmissions
.

4
.
With
ATF
at
specified
temperature,
add
(luid
until
it
spilis
from
fill
hole
.

WARNING
-

HotATFcan
scald
.
Weareye
protection
and
protec-
tive
clothing
and
gloves
duringthe
check
.
If
thetransmission
was
overfilled,
hot
ATF
will
spill
from
the
filler
hole
when
the
fill
plug
is
removed
.

5
.
Reinstall
fill
plug
using
new
sealing
ring
.

TRANSMISSION
SERVICE

011743

0011742

Fig
.
2
.



ATF
drain
plug
(A)
and
fill
plug
(B)
on
A5S
310Z
transmission
.

Tightening
Torques

"
ATF
fill
plug
to
ATF
sump

MS
270R/A4S
31
OR
.............
33
Nm
(24
ft-Ib)
MS
310Z
(M30
plug)
............
100
Nm
(74
ft-Ib)

The
procedure
given
here
includes
removal
and
installation

of
the
ATF
(luid
strainer
(filter)
.

1
.
Remove
drain
plug
and
drain
fluidinto
container
.
See
Fig
.
3
or
Fig
.
2
given
earlier
.

0~
0

/\1--Z
.IZ
~
~

A



~
"o



15/

Fig
.
3
.



ATF
drain
plug
(A)
on
A4S
270R/A4S
310R
.

WARNING
-

The
ATF
must
not
be
hot
when
draining
.
Do
not
drain
the
ATF
if
the
engineandlor
transmission
Is
hot
.
Hot
ATF
can
scald
.
Wear
eye
protection,
pro-
tective
clothing
and
gloves
.

0011595

240-
6



AUTOMATIC
TRANSMISSION

14
.
Remove
transmission
by
pulling
back
and
down
.
Lower

jack
to
allow
transmission
to
clear
vehicle
.



Tightening
Torques

"
ATF
drain
plug
to
ATF
sump

CA
UTION-



MS
270R/A4S
310R
....
..
....
.
..
25
Nm
(18
ft-Ib)

Do
not
allow
the
torque
converter
to
fati
off
the



ASS
310Z(M10
plug)
..
..
..
.
.
..
.
..
16
Nm
(12
ft-Ib)

transmission
inputshaft
.



"
ATF
fill
plug
to
ATF
sump

MS
270R/A4S
310R
..
..
....
..
..
.
33
Nm
(24
ft-Ib)

15
.
Installation
is
reverse
of
removal,
noting
the
following
:



MS
310Z(M30
plug)
......
.
.
..
.
.
100
Nm
(74
ft-Ib)

"Blowoutofcoolerlineswithlow-pressurecompressed



"
ATF
cooler
lines
(A4S
270R/A4S
310R)

air
and
flush
coolerwith
clean
ATF
twice
before
reat-



Coupling
nuts
............
.
.
..
..
.
20
Nm
(15
ft-Ib)

taching
lines
to
transmission
.



Hollow
bolts
.........
.
.....
..
..
.
37
Nm
(28
ft-Ib)

"
Reinforcing
cross
brace

CAUTION-



to
chassis
(M10)
.............
.
..
.
42
Nm
(31
ft-Ib)

"
Wear
safety
glasses
when
working
with
com-



"
Torque
converter

pressedair
.



to
driveplate
(M10)
.........
..
.
..
45
Nm
(33
ft-Ib)

"
Transmissionsupport
crossmember
to
chassis

"
Do
not
reuse
ATF
after
flushing
.



M8
......................
22-24
Nm
(16-17
ft-1b)

M10
................
.
....
..
.
..
42
Nm
(31
ft-Ib)

"
Install
new
sealing
washers
on
hollow
bolts
.



"
Transmissíon
to
engine
(Torx-head
with
washer)

"
Insta¡¡
new
O-rings
on
transmission
cooler
lines,
where



M8
......................
..
.
..
21
Nm
(15
ft-Ib)

applicable
.



M10
.....................
..
..
.
42
Nm
(31
ft-Ib)

"
Inspect
driveplate
for
cracks
or
elongatedholes
.
Re-



M12
................
.
....
..
.
..
72
Nm
(53ft-Ib)

place
if
necessary
.

"
Check
to
be
sure
torque
converter
is
seated
correctly

in
transmission
during
final
installation
.

"
When
mounting
transmission
to
engine,
the
three

mounting
tabs
on
torque
converter
must
be
aligned

with
indentations
on
driveplate
.
Use
an
alignment

dowel
to
line
up
bolt
holes,
if
necessary
.
"
Fill
transmission
with
clean
ATF
until
oil
leve¡
is
even
with
fill
hole
.
Then
check
fluid
leve¡
as
described
ear-
lier
.

"
Adjust
gearshift
mechanism
.
See
250
Gearshift
link-

age
.

NOTE-

Torx-head
mounting
bolts
shouldalwaysbe
used
with
washers
to
prevent
difficult
removal
.

TRANSMISSION
REMOVAL
AND
INSTALLATION

GENERAL
.
.
.
.
.
.
.
.
.
................
.
.
.
250-1



AUTOMATIC
TRANSMISSION
GEARSHIFT
...
.
.........
.
.
.
.
.
.
.
.
.
.
.
.
.
.
250-3
MANUAL
TRANSMISSION



Gearshift
mechanism,
adjusting
GEARSHIFT
.
.
.
.
.
.
.
.....
.
..........
.
.
.
250-1



(automatictransmission)
..
.
.
.
.
.
.
.
.
.
...
.
.
250-3

Gearshift
lever,
removing



Gear
position/neutral
safety
switch,
replacing
(manual
transmission)
.
.
.
.
...
.
.
.
.......
250-1



(automatic
transmission)
..
.
.
.
.........
.
.
250-4

Gearshift
lever,
installing



Automatic
shiftlock,
checking
function
(manual
transmission)
.
.
.
.
.
.
.
.
.
.
.......
250-2



(automatic
transmission)
..
..
...
.
.
.
....
..
250-5

Shiftinterlock,
checking
function

(automatic
transmission)
.......
.
.
.
.....
.250-6

GENERAL

This
repair
group
covers
transmission
gearshift
and
linkage
service
.

Special
service
tools
are
required
for
some
of
the
proce-

dures
given
here
.
To
gain
access
to
the
complete
gearshift

mechanism
ít
is
necessary
to
remove
the
exhaust
system
and
the
driveshaft
as
described
in
180
Exhaust
System
and260
Driveshaft
.

MANUAL
TRANSMISSION
GEARSHIFT

Gearshift
lever,
removing

(manual
transmission)

The
manual
transmission
gearshift
linkage
is
shown
in
Fig
.1
.
Use
thisillustration
asaguide
when
removing
and
installing

the
linkage
.

1
.
Pull
straight
upon
shift
knob
lo
remove
it
from
shift
lever
.

NOTE
-

Removal
of
the
shift
knob
will
require
about
90
lbs
.
of
force
.

2
.
Pry
upon
rear
of
shift
boot
tounclip,
then
remove
boot
from
front
retainers
.

3
.
Raise
vehicle
togain
access
to
underside
of
vehicle
.

WARNING
-

Make
sure
thecar
is
stable
and
well
supported
at
afl
times
.
Use
a
professional
automotive
lift
orjackstands
designed
for
the
purpose
.
A
floor
jack
is
not

adequate
support
.

250
Gearshift
Linkage

GEARSHIFT
LINKAGE



250-1

Fig
.1
.



Manual
transmission
gearshift
linkage
.

4
.
Disconnect
oxygen
sensorharness
connectors
.
Re-

move
completeexhaust
system
.
See
180
Exhaust

System
.

MANUAL
TRANSMISSION
GEARSHIFT

2
.
Install
rubber
grommet
with
arrow
pointing
forward
.
In-



AUTOMATic
TRANSMISSION
stall
shift
rod
and
shift
boot
.



GEARSHIFT

NOTE-

Install
rubbergrommet
correctly
so
that
is
seals
outwa-
ter
.

4
.
Install
driveshaft
and
heat
shield
.
See
260
Driveshaft
.

Manual
valveleven
(at
transmission)

Fig
.
6
.



Automatic
transmission
gearshift
assembfy
.

Shift
cable

GEARSHIFT
LINKAGE



250-
3

The
automatic
transmission
shift
mechanism
is
shown
in
Fig
.
6
.
Use
the
illustration
as
a
guide
when
servícing
the
gear-
shift
mechanism,
including
shift
cable
replacement
.

3
.
Connect
shift
rod
to
shift
lever
.
Install
transmission

crossmember
.
Lift
transmission
and
tighten
crossmem-



Gearshift
mechanism,
adjusting
ber
bolts
.



(automatictransmission)

NOTE-



1
.
Position
selector
lever
in
Park
.

Beforeconnecting
the
shift
rod
to
the
lever,
be
sure
the



2
.
Raise
vehicle
to
gain
access
to
shift
linkage
.
gearshift
leven
is
facing
the
correct
way
as
illustrated
in
Fig
.
1
.
WARNING
-

Make
sure
thecan
is
stable
and
well
supported
at
all
times
.
Use
a
professional
automotive
lift
or
jack
stands
designed
for
the
purpose
.
5
.
Reinstall
exhaust
system
.
See
180
Exhaust
System
.
Connect
oxygen
sensor
harness
connectors
.



3
.
Loosen
selector
cable
clamping
nut
.
See
Fig
.
7
.

6
.
Lower
vehicle
.
Insta¡¡
shift
boot
cover
.
Push
shift
knob



4
.
Push
shift
lever
forwardtoward
engine(Park
position)
onto
lever
.



while
applying
light
pressure
on
cable
end
.
Tighten
ca-
ble
clamping
nut
.

Tightening
Torques



NOTE-
"
Driveshaft
to
final
drive



Do
not
overtighten
the
nut
so
that
it
twists
the
cable
.
flange
(with
U-joint)
.
..
.
.....
.
.
See
250
Driveshaft

"
Flex-disc
to
driveshaft
or

transmission
flange
...
.
.......
See
250
Driveshaft



Tightening
Torque
"
Transmission
crossmember



"
Shift
cable
clamping
nut
.......
10-12
Nm
(75-9
ft-Ib)
to
body
(M8)
.
.
.
...
..............
21
Nm
(16
ft-Ib)

/S
r\
1
1

Gear
position/
neutral
safetyswitch

Automatic
shilo
solenoid
id

AUTOMATIC
TRANSMISSION
GEARSHIFT

250-
4



GEARSHIFT
LINKAGE

r%
;
5

(((((C
"
~
;

Fig
.
7
.



Selector
lever
cable
clamping
nut
(A)
.
Counterhold
clamping
bolt
when
loosening
nut
.

Gear
position/neutral
safety
switch,

replacing
(automatic
transmission)

NOTE-

The
gear-positionlneutral
safetyswitch
is
also
some-
times
referred
to
as
the
automatic
transmission
range
switch
.

Failure
of
the
gear
positionlneutral
safetyswitch
can
cause

a
no-start
condition
.
In
acidition,
since
it
signals
gearshift
posi-

tion
tothe
transmission
control
unit,
a
faulty
switch
can
cause

erratic
transmission
operation
.

1
.
Remove
hex-head
screw
(3mm
allen
key)
from
shift
le-

ver
handle
and
remove
handle
.
Carefully
pry
up
cover

from
gearshift
lever
console
.

2
.
Disconnect
harness
connector
from
gear
positionlneu-

tral
safety
switch
andremove
mounting
screws
.
See

Fig
.
8
.

3
.
Remove
gear
positionlneutral
safety
switch
by
moving

selector
until
pin
on
lever
aligns
with
slot
on
switch
.
Pull

switch
straight
up
and
off
.
See
Fig
.
9
.

4
.
Installation
is
reverse
of
removal,
noting
the
following
:

"
Before
installing
switch,
align
plastic
contact
slide
in-

sideswitch
with
slot
in
switch
.
See
Fig
.
10
.

"
Instan
switch
so
that
contact
slide
on
switch
aligns
with

slot
on
switch
.
Then
position
gearshift
lever
pin
to
slot

on
switch
and
install
switch
.

"
When
installing
shift
lever
handle,
engage
pín
on
re
leasebutton
to
hole
in
pulí
rod
.
See
Fig
.
11
.



Fig
.
9
.



Contact
slide
in
switch
aligns
toslot
on
switch
and
pin
on
le-
ver
.

Tightening
Torques

"
Console
to
body
..............
...
.
7
Nm
(62
in-lb)

"
Gear
positionlneutral
safety
switch

to
shift
console
.................
.
4
.5
Nm
(40
in-lb)

AUTOMATIC
TRANSMISSION
GEARSHIFT

Fig
.
8
.



Disconnect
harness
connector
to
gear
position/neutral
safety

switch
by
pressing
connector
retaining
clips
together
(ar-
rows)
.
Switch
mountingscrews
shown
at
1
.