1994 BMW 325i 250

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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v

Warnings
and
Cautions
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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

100-6
ENGINE-GENERAL

Cylinder
compression,
checking

A
compression
tester
is
needed
to
make
a
compression
test
.

To
obtain
accurate
test
results,
the
battery
and
starter
must
be
capable
of
cranking
the
engine
at
250-300
rpm,
and
theen-

gine
should
be
at
normal
operating
temperature
.
Use
com-

pressed
air
to
clean
aroundthe
spark
plugs
before
removal
.

1
.
Disable
the
ignítion
system
by
removing
the
engine

management
system
main
relay
and
the
fuel
pump
re-
¡ay
.
See
Fig
.
6
.

WARNING
-

The
ignítion
system
produces
high
voltages
that
canbe
fatal
.
Avoid
contact
with
exposed
termínals
and

useextreme
caution
when
working
on
acar
wíth
the
ignítion
switched
on
or
the
engine
running
.

Fuel



DM
E
pump
main
re
ay



rel
ay
o
oa
ooa

.,
o00
oao

Fig
.
6
.



Engine
management
relays
in
power
distribution
box
inleft
rear
of
engine
compartment
.

CAUTION-

"
On
OBD
11
cars,
making
a
compression
test
may
causea
faultto
set
in
the
ECM
and
may
also
il-
luminate
the
Check
Engine
light
.
The
light
can
only
be
tumed
out
using
special
scan
tool
equip-
ment,using
eíther
the
BMW
specialservíce
tool
or
using
a
"generic"
OBD
11
scan
tool
.
Discon-
necting
the
battery
will
not
erase
the
fault
mem-
orynor
turn
outthe
light
.

0013034,

0012630

Fig
.
7
.



Remove
spark
plug
wires
from
spark
plugs
on
4-cylinder
en-
gine
using
special
tool
.
Tool
is
stored
under
cover
at
rear
of
cylinder
head
(arrow)
.

Fig
.
8
.



Remove
engine
cover
on
6-cylinder
engine
byprying
off
nut
covers
and
removing
nuts
(A)
.
Be
careful
not
to
let
rubber
in-
sulators
fall
off
as
cover
is
removed
(arrows)
.

4
.
On
6-cylinder
engines,
disconnect
the
harness
connec-
tors
from
the
ignítion
coils
by
lifting
the
retaining
clip
.

Remove
the
coil
mounting
nuts
andremove
the
six
coils
.
See
Fig
.
9
.
Remove
the
sparkplugs
.
"
Failure
to
remove
the
main
relay
or
attempting
to
disable
the
ignítion
system
by
other
methods
may
resultin
damage
to
the
engine
control
module
.



NOTE-

Used
sparkplugs
should
be
reinstalled
in
the
same
cyl-

2
.
On
4-cylinder
engine
:
Remove
plastic
engine
cover
from



inder
fromwhich
they
were
removed
.

top
of
cylinder
head
.
Disconnect
spark
plug
wires
and
re-
move
spark
plugs
.
See
Fig
.
7
.



5
.
Insta¡¡
the
compression
gauge
in
the
first
cylinder's

3
.
On
6-cylinder
engine
:
Remove
top
engine
coverby
pry-



spark
plug
hole,
tight
enough
to
form
a
good
seal
.

ing
off
nut
covers
and
removing
mounting
nuts
.
See
Fig
.
8
.

MECHANICAL
TROUBLESHOOTING

110-2



ENGINE
REMOVAL
AND
INSTALLATION

8
.
Drain
engine
coolant
andremove
coolant
hoses
at-



10
.
Remove
radiator
cooling
fan
and
radiator
as
described

tached
to
cylinder
head
.



in
170
Radiator
and
Cooling
System
.

"
Drain
radiator
and
engine
block
.
See
170
Radiator

and
Cooling
System
.



NOTE-

"
Disconnect
hoses
from
thermostat
housing
at
front
of



Some
late
4-cylinder
modelsuse
an
electric
prímary
cylinder
head
.



cooling
fan
.
"
Disconnect
heater
hoses
at
rear
of
engine
.
See
Fig
.
2
.

CAUTION-

NOTE-



On
cars
with
viscous-type
cooling
fans,
the
radia-

"
The
block
drain
plug
is
located
on
the
exhaust
side
to-



tor
fan
has
left
hand
threads
.

wards
rear
of
engine
.

"
Remove
small
plastic
lock
clíp
to
pull
radiator
drain



11
.
Remove
upper
intake
manifold,
unfasten
cable
duct

plug
out
completely
.



from
lower
intake
manifold,
crankcase
vent
valve
hose

(M44
engine
only)

0012687

Fig
.
2
.



Coolant
hoses
at
heater
valve
and
heatercore
to
be
discon-
nected
(arrows)
.

9
.
Remove
air
shroud
from
top
of
radiator
.
See
Fig
.
3
.

ENGINE
REMOVAL
AND
INSTALLATION

12
.
Disconnect
fuel
supply
and
fuel
return
lines,
main
en-

gine
electrical
connectors,
and
lower
intake
manifold
as

described
in
113
Cylinder
HeadRemoval
and
Instal-

lation
.
See
Fig
.
4
.

0012504

Fig
.
4
.



Crankcase
ventvalve
(A)
on
top
of
lower
intake
manifoldof
M44
engine
.
Fueldelivery
and
retum
lines
shown
at
B
.
Engine
harness
and
sensor
connectors
shown
at
C
.

WARNING
-

"
Fuel
may
be
expelled
under
pressure
.
Do
not
smoke
orworknear
heaters
or
other
fire
haz-
ards
.
Keep
a
fire
extinguisher
handy
.
Before
dis-
connecting
fuel
hoses,
wrap
a
cloth
around
fuel
hoses
to
absorb
any
leaking
fuel
.
Plug
all
open
fuel
lines
.

"
Always
unscrew
the
fuel
tank
cap
to
release
pres-
sure
in
the
tank
before
working
on
the
tank
or
lines
.

CAUTION-
0013137



I
Stuff
clean
rags
into
the
open
intake
ports
topre-
Fig
.
3
.



Front
air
shroud
mounting
screws
(arrows)
.



vent
any
parts
from
falling
into
the
engine
intake
.

13
.
Disconnect
vacuum
hose
from
brake
booster
on
bulk-
head
.
Cover
bothhole
in
booster
and
plug
hose
end
.

113-4



CYLINDER
HEAD
REMOVAL
AND
INSTALLATION

20
.
Disconnect
main
engine
wiring
harness
connector
.
La-

bel
and
disconnect
harness
connectors
for
crankshaft

and
camshaft
sensors
.
See
Fig
.
8
.

0012504

Fig
..
Crankcase
vent
valve
(A),
camshaft
and
crankshaft
sensor
harness
connectors
(B),
locating
bushings
(C),
main
engine
wiring
harnessconnector
(D)
.
M44
engine
shown
.

NOTE-

Early
engines
do
not
havea
maín
disconnect
at
the
lower
intake
manifold
harness
.
lf
necessary,
remove
the
cable
ducting
bolts
and
set
harness
ducting
aside
.

21
.
Remové
lower
section
of
intake
manifold
.

"
Remove
Y
shaped
supportbracket
from
underside
of
manifold
.
(See
Fig
.
6
.)
"
Unbolt
support
brackets
from
alternator
and
starter
.
"
Remove
nuts
holding
manifold
to
cylinder
head
and
pull
manifold
back
until
harness
connectors
for
oil

pressure
switch
and
coolant
temperature
sensorare

accessible
.
Label
and
disconnect
connectors,
then
re-

move
manifold
and
set
aside
.

Timing
chains,
uncoupling



26
.
Lock
crankshaft
in
TDC
position
by
insertíng
BMW
spe-

22
.
On
M42
engines,
remove
thermostat
housing
from
up-



cial
tool
no
.
11
2
300
through
bore
and
into
hole
infly-

per
timing
chaincover
.



wheel
or
driveplate
.
See
Fig
.
11
.

23
.
On
late
M44
engines
(January
1997
and
later),
remove



NOTE-
secondary
air
injection
check-valve
from
front
of
engine



"
If
necessary,
remove
plug
from
locating
bore
in
lower
and
lay
aside
.



edge
of
bell
housing
to
insert
locking
tool
.

24
.
Remove
cylinder
identification
sensor
from
upper
tim-
ing
chaincover
.
Remove
upper
timing
chaincover
.
See
Fig
.
9
.

25
.
Set
engine
to
approximate
TDC
by
rotating
in
normal
operating
direction
until
camshaft
lobes
at
cylinder
no
.
1
are
facing
each
other
.
See
Fig
.
10
.

CYLINDER
HEAD,
4-CYLINDER

Fig
.
9
.



Upper
timing
chain
cover
bolts
(arrows)
.
Remove
secondary
air
injection
check
valve
fromhose
(A)
on
M44
engine
.
Re-
move
cylinder
identification
sensor
from
chaincover
(B)
.

0011998

Fig
.
10
.
Engine
set
to
approximate
TDC
.
Cylinder
no
.
1
camshaft
lobes
face
in
and
arrows
on
sprockets
poínt
up
(arrows)
.

"
Confirm
that
the
locking
tool
has
been
correctly
in-
stalled
by
trying
to
rotate
the
crankshaft
.

27
.
Lock
camshafts
at
TDC
by
mounting
BMW
specíal
tool
no
.
113
240
over
square
ends
of
camshafts
.
See
Fig
.
12
.

NOTE-

Check
that
tool
is
squarely
seated
on
cylinder
head
gasket
surface
.
If
necessary,
rotate
camshafts
slightly
using
an
open-end
wrench
at
hex
oncamshafts
.

113-
6



CYLINDER
HEAD
REMOVAL
AND
INSTALLATION

32
.
Using
Torx
E12
socket,
remove
cylinder
head
bolts
in



2
.
Check
gasket
surface
of
cylinder
head
and
cylinder

the
sequence
indicated
.
See
Fig
.
15
.
Remove
cylinder



block
for
warpage
using
a
straight
edge
.

head
and
head
gasket
.
Discard
head
boits
.



3
.
On
M42
engine
:
Be
sure
oil
feed
check
valve
and
spac-

er
are
correctly
positioned
in
block
.
See
Fig
.
16
.

0012502

Fig
.
15
.
Cylinder
head
bolt
loosening
sequence
.
Use
Torx
El
2
socket
.

Cylinder
head,
installing

(4-cylinder
engine)

CAUTION-

If
the
camshafts
were
removedrínstalled
while
the
cylinder
head
was
off,
a
minimum
wafting
time
ís
requíred
after
installing
the
camshafts
.
When
the
camshafts
are
removed,
the
hydraulic
lifters
canexpand
.
This
expansion
can
cause
fncreased
valve
lift,
resultíng
in
open
valves
and
pfston
con-
tact

Cylinder
head
installation
waiting
times

"
Ator
above
68°F
(20°C)
...............
10
minutes
"50-68°F
(10-20°C)
.
.
..
...............
30
minutes

"
32-50°F
(0-10°C)
..
.
..
...............
75
minutes

1
.
Clean
cylinder
head
and
gasket
surfaces
of
cylinder
block
and
al¡
timing
chain
covers
.

"
Remove
al¡
foreign
matter
and
any
¡¡quid
from
bolt
holes,
then
clean
with
a
thread
chaser
.

CAUTION-

Do
not
useametal
scraper
or
wire
brush
to
clean
the
alumfnum
cylinder
head
or
pistons
.
If
neces-
sary,
useahard
wooden
or
plastic
scraper
.
Also
available
are
abrasivediscs
to
be
used
ín
conjunc-
tionwíth
an
electric
dril¡
.
Be
sure
to
use
the
correct
disc
for
the
type
of
metalbeingcleaned
.

CYLINDER
HEAD,
4-CYLINDER

Fig
.
16
.
Oil
feed
check
valve
and
spacer
used
on
M42
engine
.
Install
check
valvewíth
collar
(arrow)
facing
down
.

CAUTION-

If
the
check
valve
is
not
installed
correctly,
oil
flow
to
the
cylinder
head
would
be
restrícted
.

4
.
Place
new
cylinder
head
gasket
on
surface
of
cylinder

block
.
Check
that
two
locating
dowels
are
correctly
po-

sitioned
in
block
and
not
damaged
.

CAUTION-

The
word
"OBEN",
prfnted
on
the
gasket,
should
face
up
.

5
.
Place
new
rubber
profile
gasket
in
groove
of
front
cover
.

6
.
With
camshafts
locked
in
TDC
positionwith
BMW
spe-
cial
tool
as
described
earlier,
set
cylinder
head
in
posi-
tion
.

CAUTION-

"
The
camshafts
mustbe
focked
in
the
TDC
posi-
tion
at
the
rear
of
the
cylinder
head
with
BMW
specfal
tool
no
.
113240
before
installing
the
cyl-
inder
head
.

"
Make
sure
the
crankshaft,
which
had
been
rotat-
ed
approximately
45°
opposite
the
dfrection
of
engine
rotation,
is
still
in
thatposition
before
low-
ering
the
cyffnder
head
ínto
position
.

"
Torx-type
cylinder
head
bolts
should
not
be
re-
used
.
They
are
stretch-type
bolts
and
must
al-
waysbe
replaced
whenever
loosened
.

Fig
.
23
.
When
reinstalling
chain
tensioner
on
M44
engine,
old
oil
in
tensioner
piston
mustbe
expelled
bycompressing
piston
in
vise
.
When
compressing
piston,
only
compress
up
to
end
cir-
clip
(arrow)
.

21
.
Turn
engine
overby
hand
in
direction
of
rotation
at
least

two
fui¡
rotations
.
Reinstall
camshaft
and
crankshaft

locking
tools
to
check
engíne
timing
.
Remove
locking

tools
if
no
faults
are
found
.

22
.
Insta¡¡
upper
timingchain
cover
.

"
Install
gaskets
and
instan
cover
using
two
mounting



Tightening
Torque

bolts
.
Using
a
screwdriver,
lever
down
on
front
cover



"
Cylinder
head
cover
until
cover
gasket
surface
is
flush
with
cylinder
head



to
cylinder
head
(M6
screws)
.......
10
Nm
(89
in-lb)

gasket
surface
.
See
Fig
.
24
.
Tighten
two
bolis
.

"
Insta¡¡
and
tighten
remainder
of
bolis
.

23
.
Install
cylinder
head
cover
.

CYLINDER
HEAD
REMOVAL
AND
INSTALLATION



113-
9

0012507

Fig
.
24
.
Install
upper
timing
case
cover
with
two
bolis,
then
press

down
on
cover
so
that
top
surface
is
flush
withcylinder
head
(arrow)
.
Hold
cover
in
position
and
tighten
bolis
.

"
Clean
old
gasket
glue
from
sealing
surfaces
.
Usea

small
amount
of
3-Bond
®
1209
adhesive
or
equivalent

at
corners
of
half-moon
cut-outs
at
back
of
cylinder

head
.
See
Fig
.
25
.

NOTE-

OnM44
engines,
reptace
sea¡
for
oil
supply
tube
.
See
Fig
.
17
.)

Fig
.
25
.
Rear
of
cylinder
head
cover
showing
area
where
sealant
(ar-
rows)
should
be
applied
.
Inset
shows
cylinder
head
cover
mounting
bolt
and
insulator
assembly
:
M6
screw
(1),
rubber
damper
(2),
washer
(3)
.

24
.
Installation
of
remaining
parts
is
reverseofremoval,

noting
the
following
:

"
Make
sure
al¡
sealing
surfaces
are
clean
and
free
of
old

gasket
material
.
Install
new
intake
manifold
gasket
.

"
On
M44
engine
:
Replace
seals
above
and
below

crankcase
ventvalve
.

"
When
installing
lower
intake
manifold,
make
sure
hol-

low
locating
bushings
are
on
two
lower
studs
.

"
Reinstall
harness
connectors
for
oil
pressure
switch

and
coolant
temperature
sensor
before
installing
in-

take
manifold
.
Tighten
manifold
nuts
in
stages
.

"
Refill
cooling
system
as
described
in
170
Radiator

and
Cooling
System
.

"
Change
engine
oil
and
filter
as
described
in
020
Main-

tenance
Program
.

"
If
necessary,
adjust
accelerator
cable
.

"
Run
engine
at
approx
.
3,500
rpm
for
about
20
seconds

to
allow
hydraulic
chain
tensioner
to
fill
with
oil
.

"
Reconnect
battery
last
.

CYLINDER
HEAD,-CYLINDER

113-14



CYLINDER
HEAD
REMOVAL
AND
INSTALLATION
29
.
Remove
mounting
nuts
from
front
of
exhaustcamshaft

sprocket
.
Remove
secondary
sprockets
together
with

timing
chain
from
front
of
camshafts
.

CAUTION-

The
crankshaft
must
not
be
allowed
to
rotate
once
the
camshaft
timing
chain
is
removed
.
The
pistons
can
contact
thevalves
.

NOTE-

Do
not
remove
the
sprockets
from
the
chain
unless
these
parts
are
being
replaced
.
Wire
tie
each
sprocket
to
the
chain
to
keep
the
sprockets
timed
to
each
other
.

30
.
Unbolt
secondary
timing
chain
tensioner
from
top
of

cylinder
head
.

31
.
Remove
primary
timing
chaintensioner
from
side
of

cylinder
head
.
See
Fig
.
37
.

Fig
.
37
.
Primary
timing
chain
tensioner
(arrow)
.

WARNING
-

Remove
tensioner
slowly-¡t
ís
under
spring
pres-
sure
.

32
.
Remove
timing
chainguíde
(Tono
E8
socket)
.
See
Fig
.
38
.

33
.
Lift
primary
chain
sprocket
off
exhaust
camshaft
.
Re-
move
sprocket
from
chain
.
Suspend
chainusing
stiff
wire
.

Cylinder
head
assembly,
removing

34
.
Remove
two
mounting
bolts
holding
cylinder
head
to
lower
timing
chaincover
(Torx
E8
socket)
.
See
Fig
.
39
.

CYLINDER
HEAD,
6-CYLINDER

Fig
.
38
.
Timing
chain
guide
mounting
bolts
(arrows)
.
M50
engine
shown
.

Fig
.
39
.
Cylinder
head-to-timing
chain
covermounting
boits(arrows)
.
(Bolt
A
also
retains
secondary
chain
tensioner
.)

35
.
Using
BMMI
special
tool
no
.
11
2
250
or
an
equivalent

tool,
loosen
cylinder
head
bolts
in
several
stages
.
See
Fig
.
40
.
Discard
head
boits
.

CAUTION-

Torx-type
cylinder
head
bolts
should
not
be
re-
used
.
Theyare
stretch-type
bolts
and
must
atwaysbe
replaced
whenever
loosened
.

NOTE-

Cylinder
head,
installing

(6-cylinder
engine)

CAUTION-

If
the
camshafts
were
removed
and
installed
while

the
cylinder
head
was
off,
a
minimum
waiting
time

is
required
after
ínstalling
the
camshafts
.
When

the
camshaftsareremoved,
the
hydraullc
lifters

can
expand
.
This
expansion
can
cause
increased

valve
lift
when
the
camshafts
are
bolted
down,
re-

sulting
in
open
valves
.

Cylinder
head
installation
waiting
times

"
68°F
(20°C)
and
higher
.
.
.
..
..........
10
minutes

"
50-68°F
(10-20°C)
........
..
.........
30
minutes

"
32-50°F
(0-10
°C)
.........
...
........
75
minutes

CYLINDER
HEAD
REMOVAL
AND
INSTALLATION



113-
1
5

1
.
Clean
cylinder
head
and
gasket
surfaces
of
cylinder

block
and
al¡
timing
chain
covers
.

"
Remove
all
foreign
matter
and
any
¡¡quid
from
bolt

holes,
then
clean
with
a
thread
chaser
.

CA
UTION-

Do
not
use
ametal
scraper
or
wire
brush
to
clean

the
aluminum
cylinder
head
or
pistons
.
If
neces-
sary,
use
a
hard
wooden
or
plastic
scraper
.
Also

available
are
abrasive
discs
to
be
used
in
conjunc-
tion
with
an
electric
drill
.
Be
sure
to
use
the
correct
disc
for
the
typeof
metal
being
cleaned
.

2
.
Check
gasket
surface
of
cylinder
head
and
cylinder

block
for
warpage
using
a
straight
edge
.

NOTE-

Fig
.
40
.
Cylinder
head
bolt
loosening
sequence
.



If
the
cylinder
head
has
been
machined,a
special
0
.3

mm
thickergasketshould
be
installed
.
The
thickergas-

ket
is
available
from
an
authorized
BMW
dealer
.

BMW
special
tool
no
.
112250
is
a
thin-walled
Torx
E12

socket
wíth
anextended
reach
.
The
cylinder
head
bolts



3
.
Place
new
cylinder
head
gasket
on
cylinder
block
.

are
recessed
finto
the
head
below
the
camshaft
towers



Check
that
two
locating
dowels
are
correctly
positioned

wíth
liffle
working
space
.



in
block
and
arenot
damaged
.

36
.
Remove
crankshaft
locking
tool
(BMW
special
tool
no
.



NOTE-

11
2
300)
.
Using
the
crankshaft
vibration
damper
bolt,



The
word
"OBEN",
printed
on
the
gasket,
should
face

turn
engine
opposite
its
normal
direction
of
rotation



up
.Thecylinderheadgasketwillfitcorrectlyinonlyone

(counterclockwise
asviewed
from
the
front)
approxi-



orientation
.

mately
45°
.
This
prevents
accidental
contact
between

valves
and
pistons
during
installation
.



4
.
With
camshafts
locked
in
TDC
positionwith
BMW
spe-

cial
tools
as
described
earlier,
set
cylinder
head
in
po

NOTE-



sition,
guiding
primary
chain
through
cylinder
head
Guide
cam
chain
to
keep
it
from
jamming
when
turning



opening
.

the
crankshaft
.
CA
UTION-

"
The
camshafts
must
be
locked
in
the
MC
posi-

tion
at
the
rear
of
the
cylinder
head
with
BMW

special
tool
no
.
113240
before
installing
the
cyl-

inder
head
.

"
Make
sure
the
crankshaft,
which
had
been
rotat-

ed
approximately
45°
opposite
thedirection
of
engine
rotation,is
still
in
that
position
before
low-
ering
the
cylinder
head
into
position
.

5
.
Lightly
lubricate
new
cylinder
head
bolts
.
Loosely
instan
bolts
and
their
washers,
then
thread
them
in
until
they

are
finger
tight
.
Install
cylinder
head-to-lower
timing

chaincover
boitsfinger
tight
.

CAUTION-

Tonc-type
cylinder
head
bolts
should
not
be
re-

used
.
They
are
stretch-typebolts
and
must
always
be
replaced
whenever
loosened
.

CYLINDER
HEAD,
6-CYLINDER