1994 BMW M3 brake fluid

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
.

Fig
.
3
.



Clutch
master
cylinder
mounting
bolts
.

Clutch
slave
cylinder,
replacing

0012589

Tightening
Torques

"
Clutch
master
cylinder
to
bulkhead
..
22
Nm
(17
ft-Ib)
"
Fluid
line
to
master
cylinder

orslave
cylinder
.................
16
Nm
(12
ft-1b)

The
clutch
slave
cylinder
is
mounted
on
the
left
side
of
the

transmission
.



CLUTCH
MECHANICAL

1
.
Remove
brake
fluid
reservoir
cap
.
Using
a
clean
sy-

ringe,
remove
brake
fluid
from
reservoir
.

2
.
Disconnect
fluid
hose
from
slave
cylinder
.
Place
a
pan

under
hose
to
catch
any
excess
fluid
.

3
.
Unbolt
slave
cylinder
from
transmission
.
See
Fig
.
4
.

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

"
Check
for
wear
on
pushrod
.
Any
other
wear
except
on

tipis
caused
by
misalignment
of
clutch
components
.

"
Lightly
coat
pushrod
tip
with
molybdenum
disulfide

grease
(Molykote
0
Longterm
2
or
equivalent)
.

"
During
installation
be
sure
pushrod
tip
engages
recess

in
clutch
release
lever
.

"
Fill
fluid
reservoir
with
clean
fluid
.

"
Bleed
clutch
hydraulics
as
described
earlier
.

CLUTCH
210-
3

Fig
.
4
.



Clutch
slave
cylinder
mounting
bolts
(arrows)
.

Tablea
.
ClutchDisc
Diameter

Model



Diameter

3181/is/iC



215
mm
(8
.46
in)

325i/is/iC



228
mm
(8
.98
in)
323is/iC

328i/is/iC



240
mm
(9
.45
in)
M3

0012715

Tightening
Torques

"
Clutch
slave
cylinder

to
transmission
.
.
................
22
Nm
(17
ft
lb)
"
Fluid
line
to
slave
cylinder
......
.17
Nm
(10-12
ft
lb)

The
transmission
must
be
removed
from
the
engine
to
ac-

cess
the
clutch
mechanical
components
.
It
is
recommended

that
the
clutch
disc,
pressure
plate
and
release
bearing
be
re-

placed
duringa
clutch
overhaul
.
Be
sure
to
check
the
bottom

of
the
bellhousing
for
oil
.
If
engine
oil
is
found,
check
for
a

faulty
rear
crankshaft
oil
seal
.

CLUTCH
MECHANICAL

Selector
shaft
seal,
replacing

(transmission
instalied)

1
.
Raise
and
safely
support
vehicle
to
access
drain
plug
.

2
.
Support
transmission
with
transmission
jack
.

3
.
Remove
driveshaft
.
See
260
Driveshaft
.

4
.
Remove
transmission
crossmember
and
tilt
down
rear

of
transmission
.

CA
UTION--

Tilting
the
engine
to
lower
the
transmission
can
lead
to
damage
to
various
cgmponents
due
to
lack
of
clearance
.
-On
cars
with
AST
(traction
control)
remove
throt-
tle
body
before
tiltlng
engine
.
-Remove
brake
fluid
reservoir
lf
necessary
.

Locking
pin

á



Locking
clip

8
.
Reinstall
shift
linkage
to
selectorshaft
.

7
.
Coat
new
seal
with
transmission
fluid
.
Drive
new
seal
in

flush
with
housing
.
Use
BMW
special
seal
installation
tool
no
.
23
2
260
orequivalent
and
a
soft-faced
(plastic)

hammer
.
See
Fig
.
4
.

9
.
Fiaise
transmission
and
reinstall
crossmember
.

MANUAL
TRANSMISSION



230-
3

Seal
Selector

_
shaft

5
.
Working
at
rear
of
selector
shaft,
disconnect
shift
link-



Fig
.
3
.



Selector
shaft
oil
sea¡
being
pried
out
with
screwdriver
.

age
from
selectorshaft
.
See
Fig
.
2
.

Fig
.
4
.



Selector
shaftseal
being
installed
.

6542

0012020

Fig
.
2
.



Disconnect
shift
linkage
from
transmission
selector
shaft
by

prying
back
locking
clip
and
pushing
locking
pin
out
.



10
.
Install
driveshaft
using
new
nuts
.
See260
Driveshaft
.

6
.
Carefully
pry
sea¡
out
with
a
narrow
seal
remover
or



11
.
Check
transmission
oil
level,
topping
upas
necessary
.

small
screwdriver
.
See
Fig
.
3
.

Tightening
Torques

"
Driveshaftto
flex
disc/

final
drive
flange
..............
See
260
Driveshaft

"
Transmission
crossmember
to
chassis

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

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

TRANSMISSIONSERVICE

230-
4



MANUAL
TRANSMISSION

Output
shaft
sea¡,
replacing

(transmission
installed)

1
.
Raise
and
safely
support
vehicle
.
Support
transmission

with
transmission
jack
.

WARNING
-

"
When
raising
thecar
using
a
floor
jack
or
a
hy-
draulic
lift,
carefully
position
the
jack
pad
to
pre-vent
damaging
the
car
body
.
A
suitable
liner
(wood,
rubber,
etc
.)
should
be
placed
between
the
jack
and
the
car
to
prevent
body
damage
.

"
Watch
the
jack
closely
.
Make
sure
it
stays
stable
and
does
not
shift
or
tilt
.
As
the
car
is
raised,
the
car
may
roll
slightly
and
the
jack
may
shift
.

2
.
Remove
driveshaft
.
See
260
Driveshaft
.

3
.
Remove
transmission
crossmember
and
lower
trans-

mission
at
rear
.

CAUTION-

Tilting
the
engine
to
lower
thetransmissíon
can
lead
to
damage
to
various
componente
due
to
lackof
clearance
.
-On
cars
with
AST
(traction
control)
remove
throt-
tle
body
before
tilting
engine
.
-Remove
brake
fluid
reservoir
if
necessary
.

4
.
Bend
back
and
remove
collar
nut
lockplate
.

5
.
Hold
flange
steady
andremove
collar
lock
nut
(use

30mm
thin-walled
deep
socket
.)
See
Fig
.
5
.

Fig
.
5
.



Use
holding
tool
when
loosening
output
shaft
collar
nut
.

6
.
Remove
flange
.
If
necessary,
use
a
puller
.

7
.
Use
a
sea¡
puller
to
remove
seal
from
transmission
housing
.
See
Fig
.
6
.

8
.
Coat
new
sea¡
wíth
transmission
fluid
and
drive
into
po-
sition
until
it
is
flush
with
housing
.
See
Fig
.
7
.

TRANSMISSIONSERVICE

Fig
.
6
.



Puller
used
to
remove
transmission
seal
.

Fig
.
7
.



Output
shaftseal
being
installed
using
seal
driver
(BMW
spe-
cial
tool
no
.
232
300)
.

9
.
Reinstall
output
flange
(and
shims,
if
applicable)
to
out-

put
shaft
.

NOTE-

On
Getrag
S5D200G
and
S5D
250G
transmissions
BMW
recommends
heating
theoutputflange
to
about
176°F
(80°C)
to
aid
in
installation
.
This
canbe
done
by
placing
the
flange
in
hot
water
.

10
.
Coat
bearingsurface
ofcollar
nut
withsealer
and
install
nut
.
Tighten
collar
nut
in
two
stages
.
Insta¡¡
new
lock-
plate
.
Bend
tabs
into
flange
grooves
.

NOTE-

BMW
recommends
the
use
of
a
sealer
such
as
Loctite
®
242
when
installing
the
flange
collar
nut
to
prevent
oil
from
leaking
past
the
threads
.

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-
4



AUTOMATIC
TRANSMISSION

TRANSMISSION
REMOVALAND

INSTALLATION

Removal
and
installation
of
thetransmission
is
best
accom-

plished
on
a
lift
using
a
transmission
jack
.
Use
caution
and

safe
workshop
practices
when
working
beneath
car
and
low-

ering
transmission
.

WARNING
-

To
lift
the
vehicle
safely,
see010
Fundamentals
for
the
Do-it-Yourself
Owner
.

CAUTION-

"
Be
sure
the
vehicle
is
properly
supported
.
The
removal
of
the
transmission
may
upset
the
bal-
ance
of
the
vehicle
on
a
lift
.

"
Tilting
the
engine
to
remove
the
transmission
can
lead
to
damage
to
various
components
due
to

lack
of
clearance
.
-On
carswith
AST
remove
throttle
body
.
-Remove
brake
fluid
reservoir
if
necessary
.

Torx-head
bolts
are
used
to
mount
thetransmission
to
the

bellhousing
.
Be
sure
to
have
appropriate
tools
on
hand
before

starting
thejob
.

2
.
Install
engine
support
across
engine
bay
.
Raise
and

safely
support
vehicle
.
See
Fig
.
6
.

WARNING
-
"
When
raising
thecar
using
a
floor
jack
or
a
hy-
draulic
lift,
carefully
position
the
jack
pad
to
pre-
vent
damaging
the
car
body
.
A
suitable
liner
(wood,
rubber,
etc
.)
should
be
placed
between
the
jack
and
the
car
to
prevent
body
damage
.

"
Watch
the
jack
closely
.
Make
sure
it
stays
stable
and
does
not
shift
or
tilt
.
As
the
car
is
raised,
the
car
may
roll
slightty
and
the
jack
may
shift
.

CAUTION-

Removal
of
transmission
will
cause
engine
to
tip
unlessengine
support
is
used
.

TRANSMISSION
REMOVAL
AND
INSTALLATION

Fig
.
6
.
Engine
support
equipment
used
to
support
engine
from
above

before
removing
transmission
.

3
.
Raise
vehicle
to
gain
access
to
underside
of
car
.

4
.
Drain
ATF
from
transmission
as
described
earlier
.

5
.
Disconnect
oxygen
sensor
harness
.
Remove
exhaust

system,
and
exhaust
heat
shield
.
See
180
Exhaust

System
.

Transmission,
removing
and
installing



6
.
Remove
driveshaft
.
See
260
Driveshaft
.

1
.
Disconnect
negative
(-)
cable
from
battery
.



7
.
With
selector
lever
in
Park,
disconnect
shift
selector
le-

ver
cable
from
lever
and
remove
cable
bracket
.
Hold

CA
UTION-



linkage
clamping
bolt
stationary
when
loosening

Prior
to
disconnectiog
the
battery,
read
the
battery



clamping
nut
.
See
Fig
.
7
.

disconnection
cautions
given
at
the
front
of
this
manual
on
page
vi¡¡
.

Fig
.
7
.



Selector
lever
cable
clamping
nut
(A)
.
Loosen
cable
clamping
nut
(B)
and
remove
cable
from
bracket
.
Always
counterholdclamping
bolt
when
loosening
nut
.

250-2



GEARSHIFT
LINKAGE

5
.
Remove
driveshaft
.
See260
Driveshaft
.



9
.
Release
gearshift
lever
retaining
ring
from
below
by

turningspecial
tool
90°(
1
/4
turn)
counterclockwise
.
See

6
.
Support
transmission
with
transmission
jack
.
Remove



Fig
.
4
.

crossmember
from
rear
of
transmission
.
See
Fig
.
2
.

Fig
.
2
.



Rear
transmission
crossmember
(arrow)
.

7
.
Lower
rear
of
transmission
to
access
gearshift
linkage
.

CAUTION-

Tilting
the
engine
to
lower
thetransmission
can
lead
to
damage
to
various
componente
due
to
lackof
clearance
.
-On
cars
with
AST
remove
throttle
body
.
-Remove
brake
fluid
reservoir
if
necessary
.

0013135

8
.
Working
below
transmission,
disconnect
shift
rod
from

gearshift
lever
.
Note
washers
on
either
side
of
shift
rod

end
.
See
Fig
.
3
.

v

clip

Shift
rod

Fig
.
3
.



Pull
off
shift
rod
retaining
clip
in
direction
of
arrow
(t)
;
disen-
gage
shift
rod
from
gearshift
lever
(2)
.

MANUAL
TRANSMISSION
GEARSHIFT

BMW
Tool
No
.
25
1
110
orequivalent

Fig
.
4
.



Shift
lever
retaining
ring
being
removed
using
BMW
special

tool
25
1
110
.

10
.
Raise
transmission
and
temporarily
instan
transmission

crossmember
.

11
.
Lower
vehicle
.
Working
from
inside
passengercom-

partment,
pull
upon
gearshift
lever
to
remove
it
togeth-

erwith
retaining
ring
and
rubber
grommet
.

Gearshift
lever,
installing

(manual
transmission)

6532

1
.
Instan
shift
lever,
aligninglocking
tabs
with
openings
in

shift
console
.
Press
down
on
retaining
ring
until
it
clicks
into
place
.
See
Fig
.
5
.

\
Retaining

Fig
.
5
.



Shift
lever
retaining
ring
.
Fit
plastic
tabs
into
slots
of
shift
con-
sole(arrows)
.

300-8



SUSPENSION,
STEERING
AND
BRAKES-GENERAL

Tableb
.
Suspension
and
Steering
Troubleshooting

Symptom



1



Probable
cause
Repairs
(Repair
Groups
shown
in
bold)

Car
pulís
to
one
side,
wanders



a
.
Incorrect
tire
pressure



a
.
Check
and
correct
tire
pressures
.
020
b
.
Incorrect
wheel
alignment



b
.
Check
and
adjust
wheel
alignment
.
320
c
.
Faulty
brakes
(pulls
only
when
braking)



I
c
.
Check
for
sticking/damaged
front
caliper
.
340

Steering
heavy,
poor
return-



a
.
Worn
upper
strut
bearing(s)



a
.
Replace
strut
bearings
.
310
to-center



b
.
Incorrect
tire
pressure



b
.
Check
and
correct
tire
pressures
.
020
c
.
Power
steering
system
faulty



c
.
Check
power
steering
fluid
level
.
Test
system
pressure
.
320

Front-end
or
rear-end
vibra-



a
.
Worn
strut
cartridgesor
shock
absorbers



a
.
Replace
strut
cartridges
.
310,
330
tion
or
shimmy



b
.
Worn
suspension
bushings
(control
arm
or
trail-



b
.
Replace
worn
bushings
.
310,
330
ing
arm)
c
.
Worn
front
suspension
ball
joints
(control
arm,



c
.
Replace
worn
ball
joints
.
310
steering
arm
orsteering
tie-rod
end)d
.
Unbalanced
or
bent
wheels/tires



d
.
Balance
tires
.
Check
tiresfor
uneven
wear
pat-
terns
.
Check
wheels
for
damage
.
e
.
Loose
wheel
lug
boits



e
.
Tighten
lug
boits
to
proper
torque
.

Poor
stability,
repeated
bounc-
I
a
.
Worn
strut
cartridgesor
shock
absorbers



I
a
.
Replace
strut
cartridges
.
310,
330
ing
after
bumps,
suspension
bottoms
outeasily

Suspension
noise
(especially



a
.
Worn
front
upper
strut
bearings



a
.
Replaceupper
strut
bearings
.
310
over
bumps)



b
.
Loose
front
strut
cartridge



b
.
Check/tighten
strut
cartridge
collar
nut
.
310
c
.
Worn
suspensionbushings
(control
arm
or
trail-



c
.
Replace
worn
bushings
.
310,
330
ing
arm)d
.
Worn
stabilizer
bar
rubber
mounts



d
.
Replace
stabilizer
bar
rubber
mounts
.
310,
330
e
.
Loose
suspension
crossmember



e
.
Check
crossmember
for
damage
.
Tighten
mounting
boits
.

Uneven
ride
height



a
.
Incorrect
coil
springs



a
.
Measure
ride
height
and
replacesprings
as
re-
quired
.
310,
330
b
.
Bent
or
damaged
suspension
components



b
.
Inspect,
repair/replace
asnecessary
.
310,
330
c
.
Sagging
coil
springs



c
.
Measure
ride
height
and
replace
springs
as
re-
quired
.
310,
330

Wheel
noise,
continuous



I
a
.
Worn
wheel
bearing



I
a
.
Replacewheel
bearing
.
310,
330
growling,
may
be
more
notíce-
able
when
turning

Steering
loose,
imprecise



a
.
Incorrect
tire
pressure



a
.
Check
and
correct
tire
pressures
.
020
-



b
.
Loose
steering
gearmounting
bolt(s)



b
.
Inspect
and
tighten
boits
.
320
c
.
Worn
tie
rodend(s)



c
.
Replace
tie
rod(s)
and
align
wheels
.
320
d
.
Faulty
front
wheel
bearing



d
.
Replace
wheel
bearing
.
310
e
.
Worn
or
damaged
steering
gear



e
.
Adjust
or
replace
steering
gear
.
320
f
.
Worn
tires



f
.
Replace
tires
.
010

SUSPENSION
AND
STEERING
TROUBLESHOOTING