1994 BMW 325i Drive fluid

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
.

610-18



ELECTRICAL
COMPONENT
LOCATIONS

Tablea
.
E36
Component
Locations

Component



Model
Year



Location



Refer
to

Transmission
Control
Module



1992-1998



Right
rear
engine
compartment
behíndpanel



Fig
.
7
.

Transmission
Range
Switch
(Gear



1992-1998



Next
to
gear
shift
lever
in
center
console



Fig
.
29
.

Position/Neutra
l
Safety
Switch)

Transmission
Valve
Unít



1992-1993



In
transmission
oil
pan

Transmission
Valve
Unit



1994-1998



On
left
side
of
transmission

Trunk
Lid
Microswitch



1994-1998



In
trunk
lid

Trunk
Lid
Relay



1994-1998



Behind
glove
compartment
(convertible)



Fig
.
8
.
Fig
.
9
.

Trunk
Light
Switch



1992-1998



Left
underside
of
trunk
lid

TrunkLockMotor



1992-1998



Rear
of
luggage
compartment

UnloaderRelay



1992-1998



Inleft
splice
panel
behind
footwell
speaker
grille



Fig
.
5
.

Variable
Camshaft
Control
Module



1994-1996



I
Rear
right
side
of
engine
compartment

(VANOS)

Variable
Camshaft
Control
(VANOS)



1993-1998



Front
ofcylinder
head

Veh¡cle
Speed
Sensor



1992-1998



On
final
drive

Volume
Air
Flow
Sensor
(M42



1992-1995



Left
side
of
engine
compartment



Fig
.
7
.

Engine)

Washer
Fluid
Leve¡
Sensor



1992-1998



Right
frontof
engine
compartment

Washer
Pump



1992-1998



Right
side
of
engine
compartment
on
windshield
washer
reservoir



Fig
.
7
.

Wiper
Motor



1992-1998



Rear
engine
compartment

Wiper
Motor
Relay



1992-1998



Inleft
splice
panel
behind
footwell
speaker
grill



Fig
.
5
.

Wiper
Relay



1992-1998



(
Behind
glove
compartment



I



Fig
.
8
./
Fig
.
9
.

Wiper/Washer
Module



1992-1993



Left
side
of
footwell
under
foot
rest
(early)

Wiper/Washer
Module



1993
(late)-



Behind
glove
compartment



Fig
.
8
.
1998



1



Fig
.
9
.

ZAE
Airbag
Control
Module



1
1994-1998



1
On
center
tunnel
under
rear
seat
cushion

ZKE
IV
Control
Module



1994-1998



I
Behind
glove
compartment



Fig
.
8
.I



Fig
.
9
.

COMPONENT
LOCATIONS

ELE-40
ELECTRICAL
WIRING
DIAGRAMS

RIGHTHEADLIGHT/



RIGHT
I



FRONT
I



FOG
LIGHT



I



HIGH



I



TURN
I



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WASHER



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BEAM



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(CONSOLE)



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m



ANTI-



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--
POWER



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LOW



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I
SWITCH
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3
I
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m
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(1995)



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~
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RIGHT



WINDOW



WINDOW
I



,



_



_



_
FAN



I



(
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(-
TURN



I
-
(


HORN



LEFT



I



(
SWITCH



I



(SWITCH



I



(
SWITCH
I



(
MOTOR



LIGHT
I--
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LIGHT



LIGHT



¢~



¢~



¢~



(CONVERTIBLE)
I



I,
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I
-(



---



-

84318

ENGINE



LEFT



LEFT



CRUISE
I



I



I



rII



I



I
COOLANT
m



LOW



HORN



CONTROL
I
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I
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I
II



I
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I



_I
SWITCH



I



-
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I



I_



-I
1



1



1



8

BRN

LEFT



LEFT



LEFT
I



I



I



I



I



I
REAR



REAR



REAR
RIGHT



I



I



(
POWER



I



(
DOOR



I



(
WINDOW
I
PARK
I



I
(WINDOW
I
((CONSOLE)
I
SWITCH
I



l,



LIGHT



I



--
SWITCH



--
POWER



-
r
-
(6
DOOR)
(CONVERTIBLE(

/A
BF.

T

BRN

Ground
Distribution

1994-95
Except
318ti
(1
of
5)

I
(TEMPERATURE
-
RIGHT
I
SWITCH



)FOG
51



¢1

WINDOW
SWITCH
(C
DOOR)

I



I
REAAT



I



,
FEAR'



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,
PCHILD
ROTECTION

LEFT



FRONT



BRAKE



WIPER



THROTTLE



OW



WIPER/



LEFT
I



,
WASHER



I



(
FOG



I



(
FLUID



I



(
MOTOR



I



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I



(LBEAM



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(
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(



)
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I
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I
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I
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I
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I
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I



MODULE



_
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_



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I



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I



_(
SWITCH



I



I



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SWITCH



I



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I



(LOW
11)



TURN
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_



a



_
2



1



s
RIGHT



ASS



COMPRESSOR
t
WIPER



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BLOWER



HAZARD
I
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I
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I
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I
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II
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I
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m
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v
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IRELAV



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DIMMER



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I(
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MODULE



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SEAT
.
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,



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)
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91



6



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BRAKE



PASSENGERS



,
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G302

-
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ELE-50
ELECTRICAL
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LEFT



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DRIVER'S



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I
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10441
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IHORN
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,



R



I



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BEAM



,



"-'



RIGHT



LIGHT



I



,
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I



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LEFT
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I



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Ground
Distribution

1998Except
318ti
(1
of
4)

~
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HK
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STEM
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2
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INTERIOR
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-
BLU/BRN
EXTERIOR
LIGHTS
SYSTEM
A14
4
BLU/GRN
j~
EXTERIOR
LIGHTS
SYSTEM
5
GRVIBRN
~~
TRANSMISSION
SYSTEM
67

INSTRUMENT
CLUSTER

10462
8

ELECTRICAL
WIRING
DIAGRAMS
ELE-167

Instrument
Panel

1998
Except
318ti
(1
of2)

11
WHT/VEL
12
WHT/VIO
13
BRN/RED
14
BLUIBLK
I
SUPPLEMENTAL
1



RESTRAINTS
SYSTEM
ifi
GRV
17
BRN/GR
18
BRNIVIO
19
YEL

HOTAT



HOTINRUN
HOTINACC,
HOTINRUN
ALLTIMEE



ANDSTART



RUNAND
START



ANDSTART
IGNITION



r



FUSE



FUSE



FUSE
1
FRONTPOWER
SWITCH



I
DISTRIBUTION
BOX
I



I



I
~
F27



~F46



~
F23
I
LOCK



_START
I



L



SA
----



15A
---
EA
-
J
I
ACC
*
RUN
I
1



1
.'f



32Y



BY
L------IJ



GRNII



viol
I



GRNII
VEL
I



BILL
I

ENGINE
CONTROLS
SYSTEM

GRN

DATA
LINK
CONNECTOR15Y
20Y
7Y
j
G
I
QI

viol



GF
.1
VEL



BILL

1



VIO
GRNI



I



I
I



I



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BLU/
BFN
BRN/
VID/VEL
I



I



I'D

ENGINE



DRIVER'S



BRAKE
FLUID
COOLANT
~~
I
SEAT
I



LEVELSWITCH
TEMPERATURE
I



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Ij
SJSWITCH
I

BLUR



BRNI
DR
.
BILL//



1
ORGI



SPIN

BRNIRED

BRN/GRN

YEL

RED/VEL

2

10
WHT/GRV
89-



l11



GRV



0
BODY
COMPUTER
SYSTEMSVSTEM
J



-
I
ANTI-LOCK
BRAKESSYSTEM
12



BLU/BPN



ANTI-
LOCK
BRAKESSYSTEM
13
GRNIREO
1~ENGINE
CONTROLS
SYSTEM
14
BLU/VIO/VEL
15
WHTIGRN



GRNIBLU
71
16
VIO/VEL
I
812



17
BRN/VEL
18
BRN/VIO
B73



19
BRN/GRN
20
B14



21
GRV/BLK/VELANTI-LOCK
22
BLD
i
IBLK
BRAKESSVSTEM
B16



23
BRN/GRV/VEL



BRNIGRY/VEL
B
24
BLU/VIO/WHT



BLUIVIOIWH7
9

83364

L
J



23
GRN/VIO



-



BLK/WHT
8
24
BRN/ORG



BRNISLK
9
A22



,
25



I



-



BLK/RED



10
26
SPEEDOMETER



B18
CONNA
-
ENGINE
CONTROLS
SYSTEM
(1997
ONLY)
1
WHT/RED
I



'
,,II
I
WHT/GRN
G
REDUI
II



11
VIOIYEL
B4



/
2



BLK/WHT
123
BRN



1
1
11111111



BRN/YEL
13
B77



;
4



GRN/BLU



~ITI
II



IIIIII



BRN/VIO



14

TACHOMETER



818



6
BLU



STARTING/
7



CHARGINGSYSTEM



BRN/YEL
15
A20



6
YEL/8RN
HEADLIGHTSSVSTEM
9
BLK/REO
10
11
GRY/BLK/YEL
ANTI-LOCK
BRAKESSYSTEM
21



12
BLU/BRN
ANTI-LOCK
BRAKESSYSTEM
(1997ONLY)
13
GRN/RED
Cl



14
BLU/VIO/YEL



BLU/VIO/YEL
2LI
\
.I
i
B
L
N



.
II
~
15
WHT/GRN
BRN
16



VIO/YEL



-
-
I
DRIVER'S
SEAT
BELT
SWITCH



j
17
BRNIYEL



.BRN



G203
18
BRN/VIO



GRY/BLK/YEL



BRN
19



BRNIGRN



1997



ANTI-LOCK



W/pqC~
W



j_
p20220
pqy



ONLY
BRAKES
pqy/BLKIVEL
21



(OR
BRN)



SYSTEM



(
r



OR
22
BLU/BLK
23
BRN/GRV/YEL



B
RN/GRY/YEL
.
16
2425



BRN/REO
17
823
.1
28
CONN.



BRN
12
I
I



III



III



_
1
BRN/YEL
BLU/
I



BRN
I



BRN
2



BL
[
BRN/B



I



I
I
IGNITION
3
LK
4



SRN
/RED



,
,SWITCH
G202
5
YEL/WHT

INSTRUMENT
CLUSTER

Instrument
Panel

1995-97
318ti
(1
of
2)

ELECTRICAL
WIRING
DIAGRAMS
ELE-169

HOTATALLTIMES



HOTINRUNANDSTART
HOTATALLTIMES
-~
IGNITION



RRONTPOWER
I



(
SWITCH



r



G27
E



q31
E



I
DISTRIBUTION
BOX
LOCK



START



LOCK



START
i



L



5A
-----



SA_
J
I
ACCRUNACC
RUN
I



14



2
GN/)



REO/
10
EXCEPT
GRN



1997



VIO



V



Y
EL

RED/WHT
1
(ORWHT)
2
GRV/RED
3
BLU/BRN
4
SLUIGRN
5
GAY/BAN
B
EXCEPT
7
1997
8GRY
RED/YEL
ENGINE
CONTROLS
SYSTEM



RED/YEL
1997ONLY
-
"
I



RED/YEL
1011
WHT/YEL



WHTIVEL
4
12
WHT/VIO



WHT/VIO
5
1314
BLU/BLK
SUPPLEMENTAIL
RESTRAINTSSYSTEM
15
V10
ECONTROLS
NGINECOTROLSSYSTEM
17
8RN/GRN
18
BAN/VI0
19
YEL



YEL
B
20
BLK
21
WHT/BLK



ENGINECONTROLSSYSTEM
ENGINECONTROLSSYSTEM
22
RED/YEL



GRN/BLU
7

7
EXCEPT
8
1997
9
10I



V



RN/
I



/



I
B
RNGR



NI
m
I



BRN/GRN
11



(OR
B(N/G
N)81
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4



,
12



O
CONNC



I
3I



OIL



PARK



IBRAKEFLUID
LEVEL
SWITCH
/j



/~
PRESSURE



BRAKE



LEVELWITCH
2
SWITCH



V~
SWITCH
7
1)NORMAL
2)
0
.2--BAR

j
G202

HEADLIGHTS
SYSTEM
INTERIORLIGHTS
SYSTEM
EXTERIOR
LIGHTS
SYSTEM
EXTERIOR
LIGHTS
SYSTEM
TRANSMISSION
SYSTEM
EXTERIOR
LIGHTS
SYSTEM

HEADLIGHTS
SYSTEM

.1L



j
GROUND



GROUND

NCAI



NCAI
I
BRN

N
A
IDBS
H
FUEL
B12



CONSUMPTIONMETER

ASC
.T
IND

10458
0

SRS
IND

INSTRUMENT
CLUSTER

I



OF
.,1



WHT



GRN



VIO/
r
I
BLU
YEL
2
GRHEADLIGHTSSYSTEM
INTERIOR
LIGHTS
SYSTEM
SS
BLUIBRN
EXTERIORLIGHTSSYSTEM
~I
9



BLU/GRN



,
EXTERIORLIGHTS
SYSTEM

,SUPPLEMENTAL
15



RESTRAINTS
SYSTEM
16
GRV
~~
ENGINE
CONTROLS
SVSTEM
17
BRN/GRN
18
BRN/VIO
19
YEL
20
BILK
ENGINE
CONTROLS
SYSTEM
21
12
BLU/BRN
~--*
gNTI-LOCK
BRAKESSYSTEM
13
GRNIRED
ENGINECONTROLS
SYSTEM
10



BLU/VIO/V
EL
15~HT/GRN

17
1



B
RNI
El
}
~WEL
18~
BN/VIO
19
FNIGR
N2021



GRV/BLK/YEL
~
ANTI-LOCKBRAKES
22
BLU/BLK



SYSTEM

Instrument
Panel
1998
318ti
(1
of
2)

ELECTRICAL
WIRING
DIAGRAMS
ELE-171

HOTAT



HOTINRUN
HOTINRUN
HOTINACC,
ALLTIMES



ANDSTARTANDSTART
RUNANDSTART
r
---



,
IGNITION



r



FUSE



USE



USE
1
FRONTPOWER
SWITCH



F27



F23



F4B



DISTRIBUTION
BOX
~
I
LOCK/



START
I



L



=A
----



5=
----



15=
J
I
ACC
*
8U"



By



212Y
L------



j



ORN/



GFN/
I



VI01
I
1



VIO



BLU
I



YEL'
DATA
LINK
CONNECTOR
7
Y
"=W=
TIGR
_J

BV
O
/I



B
YEL
I



VIOBYEL
I



I



B
V10

I
`
s
jSWITCH
I
L
1
,

BRNI



GRNI

BRN



BRN

BRN/YEL
BRNIBLK
BRN/RED

ENGINE



DRIVER'S



BRAKEFLUID
COOLANT
1~
I
SEAT
I



LEVELSWITCH
TEMPERATURE
I



(BELT

78
10