1996 BMW 325i Light switch

130-20



FUEL
INJECTION

Fig
.
29
.
Throttleposition
sensor
terminal
identification
on
M50
engine
.

Tableg
.
Throttle
Position
Sensor
Tests

(DME3
.113
.3
.1)

Test
conditions



I
Terminals



I
Testvalue

Harness
connector



13
andground



15
VDC
(approx
.)
disconnected,
igni-



in
harness
tion
on



connector

Harness
connector



1
and3
at
sen-
14
k
ohms
(approx
.)
disconnected,
igni-



sor
terminals
tion
off

Throttle
plate
rotat-



1
and
2
at
sen-



Variable
from
1
-
4ked
from
¡dieto
full



sor
terminals



ohms
(approx
.)
with-
throttle
position



out
interruption



¡die
Speed
Control
Valve
Coil
Resistance
Values

"
M50/S50US
engine

NOTE-



Terminals
1
and
2
..
.
................
20
t
5
ohms

On
cars
with
tractioncontrol,
do
not
confuse
the
throttle



Terminals
2
and
3
...................
20
t5
ohms
position
sensor
on
the
main
throttle
body
with
the
throt-



Terminals
1
and
3
..
.
..
:
............
.40
t
5
ohms
tle
positionswitch
on
the
secondary
throttle
body,
where
applicable
.

¡die
speed
control
valve,
testing

¡die
speed
is
maintained
by
the
ECM
through
the
¡die
speed
control
valve
.
The
¡die
controlfunction
compensates
for
engine
load
and
engine
operating
conditions
.
¡die
speed
is
adaptive
through
the
ECM
and
no
¡die
speed
adjustments
can
be
made
.

NOTE-
Before
testing
the
valve,
confirm
that
the
throttle
position



The
idle
speed
controlvalve
receives
positive
(+)
bat-
sensor
is
working
correctly
.



tery
voltage
from
the
main
relay
.

BOSCH
DME
M3
.
1
AND
M3
.3
.1
COMPONENT
TESTS
AND
REPAIRS

NOTE-

"
The
tests
given
below
are
electrical
checks
only
.
They

do
not
check
the
mechanical
operation
of
the
valve
.
If
the
valve
is
suspected
of
causing
poor
idie,
substitut-
ing
a
known
good
valve
is
the
best
way
to
check
for
a
mechanical
fault
.

1
.
With
engine
running,
check
that
¡die
speed
control

valve
is
buzzing
.

2
.
Turn
on
A/C
or
shift
car
finto
drive
.
¡die
should
remain
steady
orincrease
slightly
.

3
.
If
valve
is
not
buzzing,or
if
¡die
decreases
in
step
2,

stop
engine
and
disconnect
harness
connector
from
valve
.
Check
resistance
of
valve
across
its
terminals
.

See
Fig
.
30
.
Test
values
are
listed
below
.

NOTE
-

If
you
suspect
an
intermittent
fault,
lightly
tapthe
valve
while
testing
resistance
.

11250

Fig
.
30
.
¡die
speed
control
valve
terminal
identification
.

4
.
With
valve
harnessconnector
disconnected,
check
for
battery
voltage
at
red/white
wire
in
connector
with
igni-

tion
tumed
on
.

"
If
there
is
no
voltage,
check
wiring
between
connec-
tor
and
main
relayterminal
87
.
See
Electrical
Wiring
Diagrams
.

5
.
If
voltage
is
presentas
described
above,
check
wiring
between
ECM
and
valve
.
If
no
wiring
faults
are
found,
check
ECM
signal
to
valve
.

230
Manual
Transmission

MANUAL
TRANSMISSION



230-1

GENERAL
...
.
............
.
.......
.
.
.
.
230-1



Output
shaft
sea¡,
replacing

(transmission
installed)
....
.
.....
.
.....
.230-4

TRANSMISSION
FLUID
SERVICE
.
.
.
.
.
.
.230-1



Inputshaft
sea¡,
replacing

Transmission
fluid
leve¡,
checking
...
.
...
.
.
230-2



(transmission
removed)
.
.
.
.
...
.
.
.
.....
.
230-5
Transmission
fluid,
replacing
.........
.
.
.
.
230-2



TRANSMISSION
REMOVAL
AND

TRANSMISSION
SERVICE
.
.
.....
.
.
.
.
.
.
230-2



INSTALLATION
.
.
.
.
.
.
.....
.
.
.
.
.
.
.
.....
.
230-5

Back-up
light
switch,
replacing
.
.
.
...
.
.
.
.
.
.
230-2



Transmission,
removing
and
installing
...
.
.
.
.
230-6



_

Selector
shaft
sea¡,
replacing

(transmission
installed)
.
.
.
.
.
.
.
.
.
.
.
...
.
.
230-3



TAB

a
.
Manual
Transmission
Gear
Ratios
.
.
.
.........
.230-1

GENERAL



TRANSMISSION
FLUID
SERVICE

This
repair
group
covers
external
transmission
service,
in-



The
manual
transmissions
installed
in
the
E36
models
are

cluding
removal
and
installation
of
thetransmission
unit
.
Inter-



normally
filled
with
automatic
transmission
fluid
(ATF),
al-

nal
transmission
repair
is
not
covered
.
Special
press
tools
and



though
alternative
lubricants
may
have
beenused
from
the

procedures
are
required
to
disassemble
and
service
the
inter-



factory,
depending
on
transmission
type
and
model
year
.
For

nal
geartrain
.



example,
transmissions
fitted
to
the
M3
models
are
normally

filled
with
a
"lifetime"
manual
transmission
fluid
(BMW
MTF

Manual
transmissions
used
are
based
on
engine
applica-



LT-1)
and
do
not
require
periodic
fluid
changes
.

tion
.
Consult
200
Transmission-General
for
transmission

application
information
.
Table
a
lists
gear
ratio
specifications
.



NOTE-

The
transmission
lubricant
type
can
be
found
ona
label

NOTE-



on
the
sideof
the
transmission
.
Consult
an
authorized

Do
not
rely
on
forged
casting
numbers
for
transmission



BMW
dealer
for
altemate
fluid
use
and
the
most-up-to-

code
identification
.



date
information
regarding
transmission
operating
fluids
.

Tablea
.
Manual
Transmission
Gear
Ratios

Transmission



1



Getrag
S5D
200
G



1



Getrag
SSD
250
G



1



ZF
S5D
310
Z



1



ZF
S5D
320
Z

Gear
Ratios
:
1st



4
.23



4
.23



4
.20



4
.20
2nd



2
.52



2
.52



2
.49



2
.49
3rd



1
.66



1
.66



1
.66



1
.664th



1
.22



1
.22



1
.24



1
.24
5th



1
.00



1
.00



1
.00



1
.00

reverse



4
.04



4
.04



3
.89



3
.89

TRANSMISSION
FLUID
SERVICE

230-2



MANUAL
TRANSMISSION

Transmission
fluidleve¡,
checking

Checking
thetransmission
oil
level
involves
simply
remov-
ing
the
side
drain
plug
and
inserting
a
finger
into
the
holeto
check
the
fluid
leve¡
.
lf
the
fluid
leve¡
is
up
to
the
bottom
of
the
drain
hole
(finger
is
wetted
by
transmission
fluid),
the
leve¡
is

correct
.

Transmission
fluid,
replacing

NOTE-

Manual
transmission
fluid
type
should
be
printed
ona
label
on
the
side
of
the
transmission
.
If
in
doubt,
consult
an
authorized
BMW
dealer
for
the
up-to-dateinforma-
tion
on
operating
fluids
.

1
.
Drive
vehicle
for
afew
miles
to
warm
transmission
.

2
.
Raise
and
safely
support
vehicle
to
access
drain
plug
.

WARNING
-

"
When
raising
the
car
uslng
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
shíít
or
tilt
.
As
the
car
is
raised,
the
car
may
roll
slightly
and
the
jack
may
shift
.

3
.
Place
a
drain
pan
under
transmission
andremove
drain
plug
at
bottom
of
transmission
.
See
Fig
.
1
.

Fig
.
1
.



Manual
transmission
fill
(1)
and
drain
plugs
(2)
.

TRANSMISSION
SERVICE

4
.
Install
and
torque
drain
plug
.

5
.
Remove
fill
plug
from
side
of
transmission
.
Slowly
fill

transmission
with
fluiduntilfluid
overflows
fill
hole
.

6
.
Install
and
torque
fluid
fill
plug
.

Fluid
Capacity

"
Getrag
transmission
...........
1
.0
liter
(1.1
US
qts)

"
ZF
transmission
.............
1
.2
liters(1
.3
US
qts)

Tightening
Torque

"
Transmission
drain
or
fill
plug
.......
50
Nm
(37
ft-Ib)

TRANSMISSION
SERVICE

Back-up
light
switch,
replacing

1
.
Raise
and
safely
support
vehicle
to
accessback-up

light
switch
.

NOTE-

"
The
back-up
light
switch
on
Getrag
transmissions
is
in
the
left
rearof
the
transmission
.

"
Theback-up
light
switch
on
ZF
transmission
isin
the
rightfront
of
thetransmission
.

2
.
Unscrew
switch
from
transmission
.

3
.
Install
new
switch
.

Tightening
Torque

"
Back-up
light
switch

to
transmission
..
..
.
.....
.
..
.....
20
Nm
(15
ft-ib)

4
.
Check
transmission
fluid
leve¡
before
lowering
vehicle
.

230-
6



MANUAL
TRANSMISSION

Transmission,
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
viii
.

2
.
Insta¡¡
enginesupportacrossengine
bay
.
Raise
engine

so
that
weight
of
engine
ís
supported
.
See
Fig
.
10
.

Fig
.
10
.
Engine
support
equipment
used
to
support
engine
from
above
before
removing
transmission
.

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

4
.
Support
transmission
with
transmission
jack
.
lf
applica-
ble,
remove
reinforcing
cross
brace
from
belowen-
gine/transmission
.

5
.
Disconnect
harnesscon
nector
from
reverse
light
switch
on
transmission
.

6
.
Remove
completeexhaustsystem
and
heat
shield
.
See
180
Exhaust
System
.

NOTE-

Disconnect
oxygensensor
hamess
connector(s)be-
fore
lowering
exhaust
system
.

7
.
Remove
driveshaft
.
See260
Driveshaft
.

8
.
Disconnect
shift
rod
from
transmission
selectorshaft
.
See
Fig
.
11
.

9
.
Disconnect
shift
console
fromtop
of
transmission
.
See
250
Gearshift
Linkage
.

TRANSMISSION
REMOVAL
AND
INSTALLATION

Washers

Shift



Shift
rod

rod



retaining
clip

0
0
,

Fig
.
11
.
Shift
lever
to
transmission
connection
.

Shift
console

0012024

10
.
Unbolt
clutch
slave
cylinder
from
sideof
transmission
.

Do
not
disconnect
fluid
hose
.
Suspend
slavecylinder

from
chassis
using
stiff
wire
.

CAUTION-

Do
not
operate
clutch
pedal
with
slave
cylinder
re-
moved
from
transmission
.

11
.
Support
transmission
from
below
with
jack
.
Remove
rear

support
crossmember
from
transmission
.
See
Fig
.
12
.

Fig
.
12
.
Rear
transmission
crossmember
(arrow)
.

12
.
Lower
transmission/engine
assembly
until
it
rests
on
front
suspension
crossmember
.

CAUTION-

Tilting
the
engine
to
lower
thetransmission
can
lead
to
damage
to
various
componente
due
to
lackof
clearance
at
rear
of
engine
-On
cars
with
AST
remove
throttle
body
before
tilt-
ing
engine
.
-Remove
brace
fluid
reservoir
if
necessary
.

0013135

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

NOTE-

The
traction
control
system
referred
to
as
AST
(all
sea-
son
traction)
may
also
be
referred
to
as
ASC
(Automat-
ic
Stability
Control)
and
ASC+T
(Automatic
Stability
Control+Traction)
.

The
AST
system
improves
traction
by
electronically
apply-

ing
the
rear
brakes
when
therear
drive
wheels
are
spinning
at

a
faster
rate
than
the
front
wheels
.
The
combined
ABS/AST

control
module,
operating
through
the
ABS
hydraulic
control

unit,
modulates
braking
force
at
therear
wheels
.

In
addition,
AST
uses
retarded
ignition
timing
and
an
auxil-iary
engine
throttle
plate
to
reduceengine
torque
and
maintain

vehicle
stability
.

The
auxiliary
throttle
plate
is
held
open
by
spring
pressure
.

The
AST
system
actívates
the
auxiliary
throttie
position
motor

(ADS)
to
cose
the
AST
throttle
as
needed
.
This
reduces
the

volume
of
engine
intake
air
.
Due
to
the
throttle
closing
very
rapidly
during
AST
operationthe
driver
cannot
increase
theengine
power
output
regardless
of
how
far
theaccelerator
pedal
is
pushed
to
the
floor
.

The
auxiliary
throttle
plate
is
placed
ahead
of
the
conven-

tional
throttle
plate
in
the
throttle
body
.

Traction
control
also
comes
into
operationduringdecelera-
tion
.
Decelerating
on
snowy
or
icy
road
surfaces
can
lead
to
rear
wheel
slip
.
If
a
rear
wheel
startsto
drag
or
lock
up
when

the
throttle
is
closed
rapidly
orduringdownshifting,the
AST
system
can
limit
the
problem
by
advancing
the
ignition
timing
.

A
switch
on
the
center
console
is
used
to
togglethe
AST
on

or
off
.

The
AST
system
is
designed
to
be
maintenance
free
.
There

are
no
adjustments
that
can
be
made
.
Repair
and
trouble-
shooting
of
the
AST
system
requires
special
test
equipment

andknowledgeand
should
be
performed
only
by
an
autho-

rized
BMW
dealer
.
Table
a
lists
theconditions
indicated
by

the
AST
indicator
light
in
the
instrument
cluster

SUSPENSION,
STEERING
AND
BRAKES-GENERAL



300-5

Tablea
.
AST
Indicator
Lamp
Function

Indicator
lamp



1
Condition



1
Comment

Light
on



Normal
AST
start-



Automatic
AST
up



self-test

Light
off



AST
monitoring



Automatic
AST
op-
mode



eration

Press
AST
button,



AST
off
(disabled)



Rocking
the
car
tolight
comes
on



getout
of
snow
or
other
loose
surface
Driving
with
snow
chains

Press
AST
button
:



AST
monitoring



Automatic
AST
op-
light
goes
out



I
mode



eration

Light
flashes



AST
active
mode



I
Normal
AST
oper-
ation
as
it
controls
wheel
speed

Light
stays
on
af-



Defect
in
AST



Consult
BMW
ter
start
up
or



dealer
for
diagno-
comes
on
while



sis/repair
driving



(Vehicle
operation
remains
normal)

WARNING
-

Even
a
car
with
AST
is
subject
to
the
normal
physi-
cal
laws
.
Avoid
excessive
speeds
for
the
road
con-
ditions
encountered
.

CAUTION-
"
If
the
tires
on
the
carare
of
different
makes,
the
AST
system
may
over-react
.
Only
fit
tires
of
the
same
make
and
tread
pattem,

"In
adverse
conditions,
such
as
trying
to
rock
the
car
outof
deep
snow
or
another
soft
surface,
or
when
snow
chainsare
fitted,
it
is
advisable
to
switch
off
AST
and
allow
the
cars
driveline
to
op-
erate
conventionally
.

INTEGRATED
SYSTEMS

300-6



SUSPENSION,
STEERING
AND
BRAKES-GENERAL

BATTE
RY

KL
30

ECM
MAIN
C~
RELAY



KL
15

DSC
SWITCH

LF1
;1~lZZ~



nSLn

l'
z
sJ



WHEEL

RF

c_
.

LR

r_
.
>
RR

ELECTRONIC
BRAKE
LIGHT
SWITCH

SPEED

SENSORS

Fig
.
7
.



Schematic
of
AII
Season
Traction
(AST)
system
.

INTEGRATED
SYSTEMS

EDC

POWER
SUPPLY



SOLENOID
RELAY
GROUND
CONTROL

POWER
SUPPLY
I'
1
ABS
PUMP

GROUND
CONTROLÍ
F



f
iJ
RELAY

INLET
(4X)
wxxuw
OUTLET
(4X)



-=-=--



AST
AST
INTAKE
IHYDRAULIC
-
=-

SWITCHING
=---

!
99001
!J

WHEEL
SPEED
X
4

DME
II

000001
-
f



1
UNIT

AGS

IKE
&
DMEI
PARK
BREVE

771
SWITCH

M
ALTERNATOR



AUXILIARY
THROTTLE

r
`



INDICATOR



POSITION
MOTOR
(ADS)

ABSPUMP



DIAGNOSIS

RELAY



lu~~~b

0013027

6
.
Disconnect
ABS
electrical
connectors
.
Label
and
then

disconnect
brake
lines
from
hydraulic
brake
unit
.
Plug

openíngs
.
See
Fig
.
12
.

~
~
A
1/
B
'1v
C
~
F

lu
11
-ri
J
.

0013244
A
.
Right
front



F



Front
from
master
cylinder
B
.
Leftfront



R
.
Rear
from
master
cylinder
C
.
Rear

Fig
.
12
.
Brake
fluid
linesat
ABS
hydraulic
unit
.

WARNING
-

"
On
cars
with
All
Season
Traction
(AST),
special
BMW
service
equipment
is
required
to
properly
bleed
the
Antilock
Brake
System
(ABS)
.
Removal
of
the
ABS
hydraulic
unit
is
not
recommended
un-
less
this
equipment
is
available
.
For
safetyrea-
sons,
the
brake
system
on
cars
with
ABS
must

not
be
bled
using
the
procedures
described
inthis
repair
group
.

"
Do
not
mix
up
the
fluid
fines
at
the
ABS
hydraulic
unit
Label
all
connections
before
disconnecting
.

7
.
Remove
ABS
hydraulic
unit
from
engine
compartment
.

8
.
Working
inside
car,
remove
panel(s)
frombeneath

steering
column
to
access
pedal
assembly
.
See513
In-

terior
Trim
.

12
.
Make
sure
al¡
nuts,
fluid
couplings,
thread
bores
and

mating
surfaces
are
clean
.

BRAKES
340-
9

0011261

Fig
.
13
.
Brake
pedal
clevispin
and
retaining
clip
(A)
.
Brake
booster
mounting
nuts
shown
at
arrows
.

13
.
If
necessary,
mount
master
cylinder
to
vacuum
booster

using
a
new
O-ríng
and
newself-locking
nuts
.

CAUTION-

Do
not
over-torque
the
master
cylinder
mounting
bolts
.
This
could
damage
the
brake
booster
and
prevent
proper
vacuum
build-up
.

14
.
Installation
is
reverse
of
Rmoval
.

"
Bleed
brakes
as
described
earlier
.

"
Check
and,
if
necessary,
adjust
brake
light
switch

above
brake
pedal
.

Tightening
Torques

"
Brakemaster
cylinder
to

brake
booster
...........
.
..
..
...
26
Nm
(18
ft-Ib)

"
Brake
booster
to
bulkhead
.
.
..
..
...
22
Nm
(16
ft-Ib)

"
Brake
fluidline
to
master
cylinder
or

ABS
hydraulic
unit
.......
.
..
17-19
Nm
(13-14
ft-lb)
9
.
Remove
clip
and
clevis
pin
from
brake
booster
pushrod

and
disconnect
it
from
brakepedal
.
Remove
brake

booster
mounting
nuts
.
See
Fig
.
13
.
NOTE-

10
.
Working
in
engine
compartment,
remove
brake
booster



When
replacing
the
brake
booster
one-way
valve
or
together
with
master
cylinder
.



vacuum
hose,
install
the
valve
so
that
the
molded
arrow

is
pointing
toward
the
intake
manifold
.
Use
new
hose

11
.
If
booster
or
master
cylinder
O-ring
is
being
replaced,



clamps
.

disconnect
master
cylinder
from
brake
booster
.

BRAKE
BOOSTER