1994 BMW M3 torque

NOTE-

Some
cars
covered
by
this
manual
may
have
an
alter-
nate
cooling
fan
switchwith
switching
temperatures
of
176%190W
(80%88°C)
.
When
replacing
the
switch
check
theswitching
specifications,
whichshouldbe
stamped
on
the
switch
body
.

1
.
If
coolant
is
circulating
at
normal
operating
tempera-
ture,
but
auxiliary
cooling
fan
does
not
run,
disconnect
connector
from
radiator
temperature
switch
and
make
tests
listed
in
Table
c
.

Table
c
.
Auxiliary
Cooling
Fan
Temperature

Switch
Tests

Wires
jumpered



Test



Test
resuits
conditions

Black/green
(terminal2)
and



Ignition
ON



Fan
runs
on
brown
(terminal
1)



low
speed

Black/gray
(terminal
3)
and



Ignition
ON



Fan
runson
brown
(terminal



I
1)



high
speed
2
.
If
fan
runs
only
when
powered
directly
by
jumpered
connector
and
hot
coolant
is
circulating
through
radia-
tor,
radiator
temperature
switch
is
most
likelyfaulty
.
Use
a
new
sealing
ring
when
replacing
switch

Tightening
Torque

"
Temperature
switch
to
radiator
......
15
Nm
(11
ft-Ib)

3
.
If
auxiliary
fan
does
notrun
when
powered
directly,
check
for
battery
voltage
at
temperature
switch
connec-
tor
(black/green
wire)
with
ignition
on
.
If
battery
voltage
is
not
present,
check
fuses
.
See
610
Electrical
Com-
ponent
Locations
.

RADIATOR
AND
COOLING
SYSTEM



170-
5

~r~nmm
a
00
0

Fig
.
4
.



Auxiliary
radiator
cooling
fan
low
speed
relay
(1)
and
high
speed
relay
(2)
in
power
distribution
box
.
(Relay
locations
may
vary
.)

Auxiliary
Cooling
Fan
Circuit
Fuses



Fig
.
5
.
Auxiliary
radiator
fan
resistor
(arrow)
.
"
Fuse16
.
...................
..
..
...
...
.5
amp

"
Fuse
41
(ex
.
M44
w/man
.
trans)
.
..
.
..
.....
30
amp

"
Fuse
48
(M44
w/man
.
trans
.
only)
..
.
..
.....
40
amp



COOLING
SYSTEM
SERVICE

0013034

4
.
If
no
faults
are
found,
remove
low
speed
relay
and
turn



Coolant,draining
and
filling

ignition
ON
.
See
Fig
.
4
.



1
.
Remove
expansion
tank
cap
.
Set
temperature
controls
"
Check
for
power
at
terminal
30
and
terminal
86
of
relay



to
full
warm
.
socket
.

"
Reinstall
low
speed
relay
and
repeat
testat
high
speed



WARNING
-
relay
socket
.
Fix
any
wiring
faults
found
.



Allow
the
cooling
system
to
cool
before
openlng
or

On
early
productioncars
(up
to
9/92)
:
If
fan
operates
only
on



draining
the
cooling
system
.

high
speed
and
no
electrical
faults
have
been
foundup
to
this
point,
usean
ohmmeter
to
check
that
fan
resistor
is
not
electri-



2
.
Place
3
ra
allo

ug
.



beneath
radiator
drain
plug
and
re-

cally
open
.
Resistor
is
mounted
on
auxiliary
cooling
fan
housing



move
drain
plg
.
See
Fig
.
6
.

behind
front
grille
.
See
Fig
.
5
.
Wiring
diagrams
for
the
radiator

cooling
fan
canbefoundunder
Electrical
Wiring
Diagrams
.



3
.
Place
3-g



pail
beneath
rear
of
engine
blo
.
Loos-
en
and
re

mlon

ove
engine
blockcoolant
drain
plug
k
.

COOLING
SYSTEM
SERVICE

170-6



RADIATOR
AND
COOLING
SYSTEM

Fig
.
6
.



Radiator
drain
plug
(arrow)
.

WARNING
-

Coolant
is
poisonous
.
Itis
especially
lethal
to
pets
.

Cleanup
spills
immediately
and
rinse
the
area
with

water
.

NOTE
-

The
block
drain
plug
is
located
on
the
exhaust
side
of
the
engine,
near
the
reas
of
the
engine
.

4
.
Reinstall
radiator
and
engine
block
drain
plugsusing

new
sealing
washers
.
Leave
heater
controis
on
full

warm
.

5
.
Using
a
coolantmixture
of
50%
antifreeze
and
50%
dis-

tilled
water,
fill
system
slowly
On
radiator
with
integral

expansion
tank,
bleed
cooling
system
as
described
be-

low
.

NOTE-

"
Tap
water
may
cause
corrosion
of
radiator,
engine
and
coolant
hoses
.

"
Coolant
can
often
be
reused
provided
itis
clean
and
less
than
twoyears
old
.
Do
not
reuse
coolant
when
re-
placing
damaged
engine
parts
.
Contaminated
coolant
may
damage
the
engine
or
cooling
system
.

Tabled
.
Cooling
System
Capacities

Engine



j
Capacity

4-cylinder



1
6
.5
liters
(6.9
qt)

6-cylinder
M50/M52



10
liters
(10
.6
qt)
S50US/S52US



10
.5
liters
(11
.1
qt)

COOLING
SYSTEM
SERVICE

Tightehing
Torques

"
Radiator
drain
plug
to
radiator
...
2-3
Nm
(18-27
in-lb)

"
Engine
block
drain
plug
to
block



.
.
..
25
Nm
(18
ft-Ib)

Cooling
system,
bleeding

(radiator
with
integral
expansion
tank)

NOTE
-

On
radiators
with
a
separate
expansion
tank,
ableed

screw
is
not
provided
.
The
cooling
system
with
sepa-

rate
expansion
tank
is
self
bleeding
via
the
vent
hose

on
the
expansion
tank
.

Air
maybecome
trapped
in
the
system
during
filling
.

Trapped
air
can
prevent
proper
coolant
circulation
.
Whenever

the
coolant
is
drained
and
filled,
the
system
should
be
bled
of

trapped
air
.

1
.
With
engine
cold,
add
coolant
to
expansion
tank
until

level
reaches
COLD
(KALT)
mark
on
tank
.

2
.
Loosen
bleed
screw
on
radiator
expansion
tank
.
See

Fig
.
7
.

0011976

Fig
.
7
.



Cooling
system
bleed
screwon
radiator
(arrow)
.
Note
cold
level
mark
on
expansion
tank
.

3
.
M3
models
:
Loosen
bleed
screw
on
thermostathous-

ing
.

4
.
Set
temperature
controls
in
passenger
compartment
to

fui¡
warm
and
turn
ignition
on
position
(do
not
start
en-

gine)
.

5
.
Slowly
add
coolant
until
it
spills
from
bleed
screws
.

When
coolant
spillíng
from
bleed
screws
is
free
of
air

bubbies,
tighten
screws
.

6
.
Run
engine
until
it
reaches
operatíng
temperature
.
Af-

ter
engine
has
cooled,
recheck
coolant
level
and
top
up
as
necessary
.

CAUTION-

Always
use
genuine
BMW
coolant
or
its
equiva-

lent
to
avoid
the
formation
of
harmful,
clogging
de-

posits
in
the
cooling
system
.
Use
of
other
antifreeze
solutions
may
be
harmful
to
the
cooling
system
.

Tightening
Torque

"
Radiator
bleed
screw

to
thermostat
housing
...
.
.
........
8
Nm
(71
in-lb)

Belt-driven
cooling
fan,
replacing

1
.
Usinga32
mm
wrench
on
fan
clutch
nut,
turn
wrench

quickly
in
a
clockwise
direction
(working
from
front
of

car)
to
loosen
.
Spin
fan
off
pump
.
See
Fig
.
8
.

NOTE-

"
The
radiator
cooling
fan
nut(32
mm
wrench)
has
left-
hand
threads
.

"
The
nut
may
be
difficult
to
loosen
.
Use
a
tool
to
hold
the
coolant
pump
pulleystationary
.
BMW
hasa
spe-
cial
tool
forthis
purpose
(BMW
special
tool
no
.
115
030)
.

2
.
Remove
expansion
rivets
holding
shroud
to
radiator
.

See
Fig
.
9
.
Remove
fan
and
shroud
together
.

NOTE-

Store
the
removed
fan
clutch
assembly
in
an
upright
(installed)
positionto
prevent
lossof
clutch
fluid
.

RADIATOR
AND
COOLING
SYSTEM



170-
7

Fig
.
8
.



Radiatorcooling
fannut
(arrow)
.
Nuthas
left-hand
threads
.

3
.
To
replace
fan
clutch,
remove
fan
mounting
bolts
and

separate
clutch
from
fan
.
Fig
.
9
.



Fan
shroud
retaining
rivet
(arrow)
.
Pryout
center
pin
and
re

4
.
Installation
is
reverse
of
rernoval
.



move
rivet
.
Rivet
design
may
vary
depending
on
model
and

model
year
.

Tightening
Torques

"
Clutchnut
to
coolant
pump
(left-hand
threads)

Wíthout
BMW
tool
no
.
11
5
040
.....
40
Nm
(29
ft-lb)

With
BMW
tool
no
.
11
5
040
.
......
30
Nm
(22
ft-Ib)

"
Fan
to
viscous
clutch
...
.
..
.
......
10
Nm
(89
in-lb)

0013203

COOLING
SYSTEM
SERVICE

Fig
.
13
.
Version
2
auxiliary
fan
mounting
screws
(arrows)
.
Front
bumper
hasbeen
removed
.

4
.
Installation
is
reverse
of
removal
.

Thermostat,
replacing

0013146

The
coolant
thermostat
is
instalied
in
a
housing
at
the
front

of
the
cylinder
head
.
See
Fig
.
14
.

Fig
.
14
.
Coolantthermostat
and
housíng
.

NOTE-

On
M44
engines,
the
thermostat
is
integrated
into
the
thermostat
housíng
.
If
the
thermostat
requiresreplace-
ment,
the
complete
thermostathousing
mustbe
replaced
.

RADIATOR
AND
COOLING
SYSTEM



170-
9

WARNING
-

Allow
the
cooling
system
to
cool
before
opening
ordraining
the
system
.

2
.
Remove
belt-driven
cooling
fan
and
fan
shroudas
de-

scribed
earlier
.

3
.
On
M52/S52US
engines
:
Unclip
wiring
duct
retaining
clips
and
remove
duct
from
above
thermostat
housing
.

Also
remove
engine
front
lifting
bracket
.

4
.
Remove
thermostat
housing
from
front
of
engine
.
See
Fig
.
15
.

Fig
.
15
.
Thermostat
housíng
shown
removed
(6-cylinder
engine)
.

NOTE-

Some
thermostats
have
a
direction
arrowor
venthole
near
the
edge
.
Install
the
thermostat
so
that
either
the
arrow
or
hole
are
at
thetop
.

CAUTION
-

Be
sure
to
reconnect
ground
wire(s)
at
thermostat
housing
mounting
bolt,
where
applicable
.

5
.
Remove
thermostat
.
Note
thermostat
direction
and
ori-

entation
before
removing
.

6
.
Insta¡¡
new
thermostat
and/or
thermostat
housing
using

new
O-ring
and
gasket(s)
as
necessary
.

oo131ss



7
.
Installation
is
reverseof
removal
.
Fill
system
with
cool-

ant
as
described
under
Coolant,draining
and
filling
.

Tightening
Torques

1
.
Drain
radiator
as
described
above
under
Coolant,



"
Thermostat
housing
cover

draining
and
filling
.



to
housing
orcoolant
pump
..
..
....
10
Nm
(89
in-lb)

"
Engine
lifting
bracket
bolt
to
thermostat
housing

(M52/S52US
engine)(M8)
....
..
...
22
Nm
(17
ft-Ib)

COOLING
SYSTEM
SERVICE

Fig
.
19
.
Coolant
pump
being
removed
.
Thread
two
M6
bolts
(arrows)
in
evenly
to
withdraw
pump
.
(Thermostat
and
hoseshavebeen
removed
tor
visual
access
.)

8
.
Installation
is
reverse
of
removal
.

"
Be
sure
to
replace
O-ring
and
gaskets
.

"
Coat
O-ring
with
lubricant
during
installation
.

Tightening
Torque

"
Coolant
pump
to
timing
chaincover

M6
...
.
...................
..
.
.
10
Nm
(89
in-lb)

M8
.
..
.
....................
.
.
.
22
Nm
(17
ft-Ib)

"
Coolant
pump
pulley

to
coolant
pump
.................
10
Nm
(89
in-lb)

RADIATOR
SERVICE

Radiator,
removing
and
installing

1
.
Drain
radiator
as
described
earlier
.

WARNING
-

Allow
cooling
system
to
cool
before
opening
ordraining
system
.

2
.
Remove
primary
cooling
fan
(belt-driven
or
electric)
as

described
earlier
.

3
.
Disconnect
coolingfan
and
leve¡
sensor
harness
con-

nectors
from
bottom
of
radiator,
where
applicable

4
.
Disconnect
harness
connector
from
auxiliary
fandual

temperature
switch
.
See
Fig
.
20
.

5
.
Disconnect
all
coolant
hoses
from
radiator
.

RADIATOR
AND
COOLING
SYSTEM



170-11

0012500

Fig
.
20
.
Cooling
fan
dual
temperatura
switch
(arrow)
on
right
sido
of
radiator
.

6
.
Where
applicable,
disconnectautomatic
transmission
fluid
(ATF)
cooler
lines
from
radiator
.
See
Fig
.
21
.

Fig
.
21
.
Automatic
transmission
fluid
(ATF)
linos
at
radiator
.

7
.
Carefully
pryout
radiator
retaining
clips
from
top
of
ra-

diator
.
See
Fig
.
22
.

8
.
Pul¡
radiator
up
and
out
of
car
.

NOTE-

The
radiator
rests
ontwo
rubber
mounts
.
Check
that

the
mounts
do
not
stick
to
the
bottomof
the
radiator
.

RADIATOR
SERVICE

180-
4



EXHAUST
SYSTEM

Fig
.
6
.



Exhaust
system
support
bracket
on
6-cylinder
engine
.
Re-
move
bolts
(arrows)
to
separate
from
exhaust
pipe
.

Fig
.
7
.



Rubber
exhaust
system
hangers
.
Remove
hanger
by
prying
off
bracket
(arrows)
.

EXHAUST
SYSTEM
REPLACEMENT

7
.
Installation
is
reverse
of
removal
.

"
Where
necessary,
transfer
parts
from
old
system
to
re-
placement
system
.

"
Coat
manifold
studs
with
copper
paste
before
installing

nuts
.

"
Where
applicable,
tighten
front
pípewith
semi-flexible

compensator
last
when
installing
front
pipe
to
mani-

folds
.

"
Make
sure
there
is
at
least
20
mm
(
3
/4
in
.)
of
clearance

between
exhaust
systemand
car
body
at
every
point
.
"
Loosely
install
all
exhaust
system
mountinghardware
and
hangers
before
tightening
fasteners
to
their
final
torque
.

"
On
4-cylinder
engines
:
Tighten
center
mounting
flange
nuts
evenly
until
correct
dimension
is
obtained
.
See

Fig
.
8
.

ri

J%JJ

w

~~~JJJJ

1

Fig
.
8
.



On
4-cylinder
engines,
tighten
nuts
evenly
so
that
spríngs
are
preloaded
to
Dimension
A
.

NOTE-

To
prevent
exhaust
system
rattles
and
vibration,
pre-load
the
rear
clamping
brackets
in
the
íonaard
direction
.
See
Fig
.
9
.

0011937

Tightening
Torques

"
Cross
brace
to
chassis



..
.
...
.
..
..
21
Nm
(17
ft-Ib)

"
Exhaust
support
bracket

to
transmission
.
.
.
.
.......
.....,.
21
Nm
(17
ft-Ib)
"
Exhaust
system
mounting
clamps
...
15
Nm
(11
ft-Ib)

"
Front
exhaust
pipeto
exhaust
manifold
M10
nut
.
.
.
...
.
..
..............
30
Nm
(22
ft-Ib)

"
Front
exhaust
pipe
torear
pipe

M8
bolt/nut
..
....
.
..............
22
Nm
(16
ft-Ib)
with
compression
spring
................
See
Fig
.
8
"
Oxygen
sensor
to
exhaust
pipe
.....
55
Nm
(41
ft-Ib)

Dimension
A=15mm
(0
.60
in
.)

Fig
.
9
.



Preload
rear
clamping
bracket
as
specifíed
tohelp
prevent
system
rattling
.

Exhaust
manifolds,
removing
and

installing

WARNING
-

Do
not
work
under
a
lifted
car
unfess
itis
solidly
supportedonjackstands
designed
for
that
pur-
pose
.
Never
work
underacar
that
is
supported
solely
by
ajack
.

EXHAUST
SYSTEM



180-
5

2
.
On
1996
and
later
6-cylinder
engines,
disconnect
the
secondary
air
check
valve
and
eipe
from
the
exhaust
manifold
.

3
.
Unbolt
front
exhaust
pipe(s)
from
exhaust
manifold(s)
.

4
.
Remove
exhaustsupport
bracket
from
transmission
.

5
.
Loosen
andremove
nuts
fromexhaust
manifolds
and
remove
manifolds
.
Discard
nuts
and
gaskets
.

NOTE-

On
cars
wíth
oxygen
sensors
mounted
in
the
exhaust
manifolds,
usecare
when
removing
manifolds
.
Tobe
safe,
remove
the
sensors
from
the
manifolds
before
re-
moving
manifolds
.

6
.
Installation
is
reverse
of
removal
.

"
Coatexhaust
manifold
mounting
studs
with
copper
paste
before
installing
new
nuts
.
"
Insta¡¡
manifold
gaskets
with
arched
side
facing
mani-
folds
.

Always
use
new
retaining
nuts
and
gaskets
when
removing



Tightening
Torques

and
installing
the
exhaust
manifolds
.



"
Exhaust
manifold
to
cylinder
head

4-cylinder
engine
(M7
nut)
........
15
Nm
(11
ft-Ib)

1
.
With
exhaust
system
cold,raise
and
support
car
for
ac-



6-cylinder
engine
(M7
nut)
........
20
Nm
(15
ft-Ib)
cess
lo
exhaust
system
.

EXHAUST
SYSTEM
REPLACEMENT

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
.