1997 BMW 328i AC mounting

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

210-
4
CLUTCH

Clutch,
removing

1
.
Remove
transmission
fromengine
.
See230
Manual

Transmission
.

2
.
Remove
release
bearing
from
transmission
inputshaft
.

3
.
Remove
clutch
release
lever
by
sliding
it
out
from
under

spring
clip
.
See
Fig
.
5
.

Fig
.
5
.



Remove
clutch
release
lever
by
pulling
away
from
spring
clip
in
direction
of
arrow
.

4
.
Lock
flywheel
in
posítion
using
a
suitable
locking
tool
(BMW
Special
tool
no
.
11
2
170,or
equivalent)
.
See
Fig
.
6
.

Fig
.
6
.



Flywheel
locking
tool
(arrow)
installed
to
rear
of
cylinder
block
.

CLUTCH
MECHANICAL

0011581

0012008

5
.
Install
a
clutch
centering
tool
through
clutch
assembly

to
prevent
clutch
disc
from
falling
out
when
removing

pressure
plate
.
See
Fig
.
7
.

Fig
.
7
.



Clutch
centering
tool
(arrow)
shown
installed
through
clutch
disc
and
flywheel
.

6
.
Remove
six
bolts
from
perimeter
of
pressure
plate
.
Re-

move
pressure
plate
and
clutch
disc
.
See
Fig
.
8
.

Fig
.
8
.



Clutch
pressure
plate
mounting
bolts
(arrows)
.

0012009

6529

11
.
Raise
transmission
and
reinstall
transmission
cross-

member
.

12
.
Install
driveshaft
using
new
nuts
.
See
260
Driveshaft
.

13
.
Check
transmission
oil
leve¡,
topping
up
asnecessary
.

Tightening
Torques

"
Transmission
crossmember
to
chassis

M8
...............
.
...
.
..
22-24
Nm
(16-17
ft-Ib)

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

"
Transmission
outputflange
to
output
shaft



O



001202
2
Z
:Z
ZZZ~
%
_
j
Stage
I.................
..
.
..
190
Nm
(140
ft-Ib)

Stage
II
(after
loosening)
....
.
.
.
..
120
Nm
(89
ft-Ib)



Fi
g
.
9
.



Indent
at
oil
seal
housing
(1)
.
Punch
holes
in
seal
housing
at

Inputshaft
sea¡,
replacing

(transmission
removed)

Replacement
of
the
inputshaft
sea¡
requires
the
removal
of

thetransmission
from
the
vehicle
as
described
later
in
this
re-

pair
group
.

5
.
Lubricate
new
sea¡with
transmission
oil
and
drive
into

1
.
Remove
clutch
release
bearing
and
release
lever
from



placeusing
BMW
Special
Tool
no
.
23
2
430
or
equiva-

inside
bellhousing
.



lent
.

2
.
Remove
bolts
for
clutch
release-bearing
guide
sleeve,



6
.
Thoroughly
cleanguide
sleeve
mounting
bolts,
sealin

noting
bolt
lengths
.
Remove
sleeve
and
any
spacers



surfaces,
and
threads
in
case
.
Apply
sealer
(Loctite

(shims)
under
¡t
.
See
Fig
.
8
.



242
or
equivalent)
to
guide
sleeve
sealingsurface
and

bolts
.
Reinstall
guide
sleeve
and
spacer(s)
.

0011640

Fig
.
8
.



Clutch
release
bearing
guide
sleeve
bolts
.
(Getrag
transmis-

sion
shown)
.

3
.
With
transmission
on
aworkbench,
remove
input
shaft

sea¡
cover
from
inside
bel¡-housing
.

4
.
Locate
two
indents
in
seal
housing
.
Use
a
punch
or

scribe
to
punch
holes
in
housing
at
indents
.
Thread
two

sheetmetal
screws
into
holes
and
pulí
seal
out
using

screws
.
See
Fig
.
9
.

MANUAL
TRANSMISSION



230-
5

indents
anduse
sheetmetal
screw
(2)
to
pul¡
sea¡
from
trans-
mission
.

NOTE-

Use
care
not
to
scratch
or
damage
input
shaft
.
Use
a
protective
sleeve
or
tape
the
shaft
when
removing
and
installing
the
sea¡
.

Tightening
Torque

"
Guide
sleeveto
transmission

M6xl2
bolt
.......
...
.
.
.........
10
Nm
(89
in-lb)

TRANSMISSION
REMOVAL

AND
INSTALLATION

Removal
and
installation
of
the
transmission
is
best
accom-

plished
ona
lift
using
a
transmission
jack
.
The
engine
must
be

supported
from
above
using
appropriate
support
equipment
.

Thisallows
the
engine
to
pivot
on
its
mounts
to
access
theup-

perTorx-head
bolts
at
the
bellhousing
.

WARNING
-

"
Make
sure
thecar
is
stable
and
well
supported
at

all
times
.
Use
a
professional
automotive
lift
or
jack
stands
designed
for
the
purpose
.
A
floor
jack
is
not
adequate
support
.

"
The
removal
of
the
transmission
may
upset
the

balance
of
the
vehicle
ona
líft
.

TRANSMISSION
REMOVAL
AND
INSTALLATION

13
.
Remove
transmission
mounting
bolts
(Torx-head)
.

Note
length
and
location
of
bolts
.
See
Fig
.
13
.

Fig
.
13
.
Transmission
mounting
bolts
.

0611642

CA
UTION-

Atno
time
should
the
weight
of
thetransmission
be
supported
by
the
transmission
inputshaft
.

NOTE
-

Washers
should
always
be
used
with
Torx-head
bolts
.

Installing
bolts
without
washers
will
make
them
difficult

to
loosen
.

MANUAL
TRANSMISSION



230-
7

Fig
.
14
.
Bellhousing
alignment
dowels
(arrows)
.

16
.
Install
driveshaft
and
preload
center
bearing
bracket
.

Usenew
nuts
when
mounting
driveshaft
to
transmis-

síon/flex
disc
and
final
drive
.
See
260
Driveshaft
.

17
.
Refill
transmission
with
appropriate
lubricant
before

starting
or
towingthe
car
.
See
Transmission
Fluid

Service
earlier
in
this
repair
group
.

14
.
Remove
transmission
by
pulling
backward
until
the
trans-



Tightening
Torques

mission
inputshaft
clears
the
clutch
disc
splines,
then



"
Reinforcing
cross
brace

pulí
downwards
.
Lower
jack
andremove
transmission
.



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

"
Rubber
mount
to
transmission

15
.
Installation
is
reverse
of
removal,
keeping
in
mind
the



or
bracket
nut
(M8)
.
...
.
...
.......
21
Nm
(16
ft-Ib)

following
:



"
Slave
cylinder
to
transmission
......
22
Nm
(16
ft-Ib)

"
When
installing
exchange
transmission,
transfer
parts



"
Transmission
crossmember
to
chassis

from
old
unit
to
exchange
unit



M8
...............
.
.
...
..
22-24
Nm
(16-17
ft-Ib)

"
Thoroughly
clean
inputshaft
and
clutch
disc
splines
.



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

Lightly
lubrícate
transmission
inputshaft
before
in-



"
Transmission
to
engine
(Torx-head)

stalling
.-



M8
..
..................
..
.
..
..
22
Nm
(16
ft-Ib)

"
Be
sure
bellhousing
dowels
are
correctly
located
.
See



M10
.
.................
...
.
..
..
43
Nm
(32
ft-Ib)

Fig
.
14
.



M12
.
..................
..
.
..
..
72
Nm
(53
ft-Ib)

"
Center
rear
of
transmission
in
driveshaft
tunnel
before



"
Transmission
drain/fill
plugs
.
..
.
..
..
50
Nm
(37
ft-Ib)

tightening
transmission
support
bracket
.

TRANSMISSION
REMOVAL
AND
INSTALLATION

2
.
On
MS
270R/A4S
310R
transmissions
:
Remove
front



5
.
Installation
is
reverse
of
Rmoval
.
and
rear
oil
sump
mounting
bolts
andremove
sumps



"
Always
replace
sea¡
for
drain
plug
and
al¡
gasket(s)
andand
sump
gaskets
.



O-rings
.

"
Clean
sump
and
sump
magnet(s)
using
a
lint-free

NOTE-



cloth
.

The
MS
270
R/A4S
310
R
transmissions
may
be
fitted



"
On
MS
270R/A4S310R
transmissions
:
Use
new
bolts

with
ASE
(inch)
bolts
.



at
sump
and
tighten
bolts
in-line,
one
after
other
(do
nottighten
bolts
in
a
cross-wise
pattern)
.

3
.
On
A5S
310Z
transmission
:
Remove
oil
sump
mount-



"
On
MS
310Z
transmission,
be
sureto
instan
rounded

ing
bolts
and
brackets,
noting
position
of
brackets
.
Re-



sump
clamping
brackets
at
corners
of
sump
.

move



"
Fill
transmission
with
approved
fluid
.
sump
and
sump
gasket
.



"
Check
fluid
level
as
described
under
ATF
leve¡,

4
.
Remove
ATF
otra¡ner
mount¡ng
screws
and
remove



checking
.

strainer
together
with
gasket
orO-ring
.
See
Fig
.
4
or

Fig
.
5
.

Fig
.
4
.



A4S
270R/A4S310R
fluid
strainer
mounting
boits
(arrows)
.

Fig
.
5
.



A5S
310Z
fluid
strainer
mounting
boits
(arrows)
.

0013230

AUTOMATIC
TRANSMISSION



240-
3

NOTE-

Use
newsump
bolts
purchased
from
BMW
.
Alternative-
ly,
clean
old
bolts
and
coat
with
Loctite®
thread
locking
compound
or
equivalent

Automatic
Transmission
Fluid
Capacity
(refill
only)

"
MS
270R/A4S310R
Removal
of
large
sump
only
........
3
.0liters
(3.2
qt)
Removal
ofboth
sumps
...........
5
.0liters(5
.3
qt)

"
MS
310Z
..
..
..................
3
.3liters
(3.5
qt)

Tightening
Torques

"
ATF
drain
plug
to
ATF
sump

MS
270R/A4S
310R
..........
..
25
Nm
(18
ft-Ib)

MS
310Z(M10
plug)
..........
..
16
Nm
(12
ft-Ib)

"
ATF
fill
plug
to
ATF
sump

MS
270R/A4S
310R
..........
..
33
Nm
(24
ft-Ib)

MS
310Z(M30
plug)
.....
..
..
:.
100
Nm
(74
ft-Ib)

"
ATF
strainer
to
valve
body

MS
270R/A4S
310R
.....
..
.
...
.
20
Nm
(15
ft-Ib)

MS
310Z
..............
..
.
...
..
6
Nm
(53
in-lb)

"
ATF
sump
to
transmission

MS
270R/A4S
310R
(M6)
.
..
.
..
...
12
Nm
(9
ft-¡b)

MS
310Z
(M6)
..........
..
.
..
...
6
Nm
(53
in-¡b)

TRANSMISSION
SERVICE

8
.
Disconnect
main
harness
connector
from
transmission

by
turning
its
bayonet
lock
ring
counterclockwise
.
Re-

move
wiring
harness
from
transmission
housing
.
See
Fig
.
8
.

Fig
.
8
.



Harness
connector
at
automatic
transmission
.

9
.
Where
applicable,
disconnect
harness
connector
from

speed
sensor
at
top
óf
transmission
.

10
.
Disconnect
transmission
cooler
line
clamps
from
en-

gine
.
Disconnect
lines
from
transmission
.

11
.
Support
transmission
with
transmission
jack
.
Remove

reinforcing
cross
brace
(if
applicable)
and
transmission

support
crossmember
.

NOTE-

Note
installation
positionof
support
crossmember
.

12
.
Remove
access
plug
in
cover
plate
on
right
side
of
en-

gine
block
and
remove
torqueconverter
bolts
.
Turn

crankshaft
to
access
boits
.
See
Fig
.
9
.

AUTOMATIC
TRANSMISSION



240-
5

Bellhousing
access
hole

Socket
wrench

Fig
.
9
.



Access
andremove
torque
converter
boits
through
hole
in
bellhousing
cover
.

0

A

fij
13
.
Remove
bellhousing-to-engine
mounting
bolts
.
See



Fig
.
10
.
Transmission-to-engine
Torx-head
mounting
bolts
.
Fig
.
10
.

0012592

TRANSMISSION
REMOVAL
AND
INSTALLATION

240-
6



AUTOMATIC
TRANSMISSION

14
.
Remove
transmission
by
pulling
back
and
down
.
Lower

jack
to
allow
transmission
to
clear
vehicle
.



Tightening
Torques

"
ATF
drain
plug
to
ATF
sump

CA
UTION-



MS
270R/A4S
310R
....
..
....
.
..
25
Nm
(18
ft-Ib)

Do
not
allow
the
torque
converter
to
fati
off
the



ASS
310Z(M10
plug)
..
..
..
.
.
..
.
..
16
Nm
(12
ft-Ib)

transmission
inputshaft
.



"
ATF
fill
plug
to
ATF
sump

MS
270R/A4S
310R
..
..
....
..
..
.
33
Nm
(24
ft-Ib)

15
.
Installation
is
reverse
of
removal,
noting
the
following
:



MS
310Z(M30
plug)
......
.
.
..
.
.
100
Nm
(74
ft-Ib)

"Blowoutofcoolerlineswithlow-pressurecompressed



"
ATF
cooler
lines
(A4S
270R/A4S
310R)

air
and
flush
coolerwith
clean
ATF
twice
before
reat-



Coupling
nuts
............
.
.
..
..
.
20
Nm
(15
ft-Ib)

taching
lines
to
transmission
.



Hollow
bolts
.........
.
.....
..
..
.
37
Nm
(28
ft-Ib)

"
Reinforcing
cross
brace

CAUTION-



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

"
Wear
safety
glasses
when
working
with
com-



"
Torque
converter

pressedair
.



to
driveplate
(M10)
.........
..
.
..
45
Nm
(33
ft-Ib)

"
Transmissionsupport
crossmember
to
chassis

"
Do
not
reuse
ATF
after
flushing
.



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

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

"
Install
new
sealing
washers
on
hollow
bolts
.



"
Transmissíon
to
engine
(Torx-head
with
washer)

"
Insta¡¡
new
O-rings
on
transmission
cooler
lines,
where



M8
......................
..
.
..
21
Nm
(15
ft-Ib)

applicable
.



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

"
Inspect
driveplate
for
cracks
or
elongatedholes
.
Re-



M12
................
.
....
..
.
..
72
Nm
(53ft-Ib)

place
if
necessary
.

"
Check
to
be
sure
torque
converter
is
seated
correctly

in
transmission
during
final
installation
.

"
When
mounting
transmission
to
engine,
the
three

mounting
tabs
on
torque
converter
must
be
aligned

with
indentations
on
driveplate
.
Use
an
alignment

dowel
to
line
up
bolt
holes,
if
necessary
.
"
Fill
transmission
with
clean
ATF
until
oil
leve¡
is
even
with
fill
hole
.
Then
check
fluid
leve¡
as
described
ear-
lier
.

"
Adjust
gearshift
mechanism
.
See
250
Gearshift
link-

age
.

NOTE-

Torx-head
mounting
bolts
shouldalwaysbe
used
with
washers
to
prevent
difficult
removal
.

TRANSMISSION
REMOVAL
AND
INSTALLATION