1997 BMW 328i vacuum

340-
8
BRAKES

Fig
.
10
.
Brake
fluid
linesat
master
cylinder
(arrows)
.

6
.
If
fluid
reservoir
was
removed,
install
it
carefully
using
new
sealing
grommets
.

7
.
Mount
master
cylinder
to
brake
booster
using
a
new
0-
ring
and
new
self-locking
nuts
.

CAUTION-

Use
cave
not
to
over-torque
the
master
cylinder
mounting
nuts
.
This
could
damage
the
brake
booster
and
prevent
proper
vacuum
build-up
.

0012164

8
.
Connect
all
brake
fluid
lines
.
Connect
hydraulic
clutch
hose
to
brake
fluid
reservoir
.

9
.
Reconnect
fluid
leve¡
sender,
and
bleed
entire
brake
systemas
described
earlier
.

BRAKE
BOOSTER

BRAKE
BOOSTER

The
brake
booster
is
mounted
to
the
bulkhead
on
the
driver
sideofthe
engine
compartment,
directly
behind
the
brake
master
cylinder
.
See
Fig
.
11
.

0015225
Fig
.
11
.
Brake
booster
(arrow)
.
A
is
vacuum
hose
from
intake
mani-
fold
.
B
is
one-way
valve
.
Intake
manifold
vacuum
acts
ona
large
diaphragm
in
the
brake
booster
to
reducebrake
pedal
effort
.

Brake
booster,
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
vi¡¡
.

Tightening
Torque

"
Brake
master
cylinder
to



2
.
Using
a
clean
syringe,
empty
brake
(luid
reservoir
.

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



WARNING-
"
Brake
fluid
hose
to
caliper
....
17-19
Nm
(13-14
ft-Ib)



Brake
fluid
is
highly
corroslve
and
dangerous
to
the
environment
.
Dispose
of
it
properly
.

3
.
Remove
brake
fluid
level
sender
connector
from
reser-
voir
cap
.

4
.
Disconnectbrake
fluid
lines
from
master
cylinder
.
Plug
openings
.

5
.
Disconnect
engine
vacuum
hose
from
brake
booster
.

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

GENERAL
......
.
........
.
.
.
.
.
.
.
...
.
.
.
512-1



WINDOW
SERVICE,

Front
door
window,
initializing
..
.
.........
.
512-1



2-DOOR
MODELS
.
...
.
......
.
........
.512-5

WINDOW
SERVICE,



Front
door
window,
removing
and
installing

(2-door
models)



.
.
...
.
...............
.
512-5

4-DOOR
MODELS
.
.
.
.
................
.
512-2



Front
door
window,
adjusting

Front
door
window,
removing
and
installing



(2-door
models)
.
.
.
.
.
.
.........
.
.
.
...
.512-7

(4-door
models)
.
.
.
.
.
...
.
.
.
.
.
.
.
.
.
.....
512-2



Rear
vent
window
or
vent
latch,

Front
door
window,
adjusting



replacing
(2-door
models)
....
.
.
.
.
.
.
.
...
512-11

(4-door
models)
.
.
.
.
.
...
.
...
.
.
.
.
.
.....
512-3

Rear
door
window,
removing
and
installing



WINDOW
REGULATOR
SERVICE
.
.
.
..
.512-12

(4-door
models)
.
.
.
.....
.
.
.
.
...
.
.
.....
512-4



Door
window
regulator
and
motor,

Rear
door
fixed
glass,
removing
and
installing



removing
and
installing
.
.
.
...
.
.
.
.
.
.
.
.
.
.
512-12

(4-door
models)
.
.
.
.
.
...
.
.
.
.
.
.
.
.
.
.....
512-4

GENERAL



Front
door
window,
initializing

This
heading
covers
door
glass,
window
regulator
and
pow-

er
window
motor
repair
information
.
Before
proceeding
with
window
repairs,
specifically
on
late
cars
fitted
with
front
side-

impact
airbags,
read
the
procedure
through
to
determine
the

scope
of
the
repair
.

The
bonded
windshield
and
rear
glass
are
replaced
using

special
adhesives
and
tools
.
It
is
recommended
that
bonded

glass
replacement
bedone
by
a
professional
glass
installer
.

WARNING
-

"
Always
wear
hand
and
eye
protection
when
workíng
with
broken
glass
.

"
ff
a
window
is
broken,
all
of
the
glass
bits
should
be
vacuumed
out
of
the
door
cavity
.
Use
a
blunt

screwdriver
to
clean
out
any
remaining
glass
pieces
from
the
window
guide
rails
.

CAUTION-

ff
battery
power
is
lost
or
the
battery
has
been
dis-
connected,
windows
mustbe
re-initialized
.
Both
one
touch
up/down
and
pinch-protection
will
be
in-
active
until
windows
are
re-initialized
.
Sea
below
.

512
Door
Windows

DOOR
WINDOWS



512-1

The
front
door
windows
incorporate
a
pinch-protection
fea-

ture
as
well
as
one-touch
up/down
(1994
and
later
models)
.
In

order
for
these
featuresto
work
correctly,
the
mechanical
stop
reference
point
must
be
re-initialized
after
repairs
are
carried
out
.

1
.
Closedoor
and
turn
ignition
keyon
.
Fully
open
front

window
.

2
.
Fully
close
front
window
.

4
.
Repeat
for
remaining
window
.

5
.
The
windows
should
now
be
initialized
and
the
anti-

pinch
and
one-touch
up/down
functions
should
be
en-

abled
.

GENERAL

WARNING

Your
common
sense,
good
judge-
ment,
and
general
alertness
are
cru-
cial
to
safe
and
successful
service
work
.
Befcre
attempting
any
work
on
your
BMW,
read
the
warnings
and
cautions
on
page
vi¡
and
the
copyright
page
at
the
frontof
the
manual
.
Review
these
warnings
and
cautions
each
time
you
prepare
to
workon

your
BMW
.
Please
also
read
any
warnings
and
cautions
that
accom-
pany
the
procedures
in
the
manual
.

Door
glass
See
Door
windows
Door
windows
general
information
512-1
front
door
window
(2-door
models)
adjusting
512-7
removing/installing
512-5
front
door
window
(4-door
models)
initíalizing
512-1
removing/installing
512-2
rear
door
window
(4-door
models)
removing/installing
512-4
fixed
glass,
removing/installing
512-
4
rear
vent
window
or
vent
latch,
replacing
(2-door
models)
512-11
window
regulator
and
motor,
removing/installing
512-12
window
regulator
service
512-12Doorcheck
See
DoorsDoor
handle
See
Centrallocking
and
anti-theft
Door
panel
See
Doors
Doors
general
information
411-1
door
adjustment
411-2door
check,
replacing
411-2
door
panels
411-3
doors411-1
front
orrear
door,removing/installing
411-1
front
door
panel,
removing/installing

411-3
rear
door
panel,
removing/installing
411-4
rearsidepanel,
removing/installing
(two-door
model)
411-4
Drive
axle
See
Rear
suspension
Driveability
troubleshooting

See
Engine-general
Driveshaft
general
information
260-1
center
bearing
assembly,
replacing
260-6
driveshaft,
aligning
260-3
driveshaft,
installing
260-4

Driveshaft
(cont
.)
driveshaft,
removing260-4
driveshaftservice
260-3
flex-disc,
replacing
260-5
front
centering
guide,
replacing
260-7
guibo
See
flex-disc
troubleshooting260-1

ECM
(engine
control
module)
pin
assignment
See
Fuel
injection
Electrical
circuit
See
Electrical
system-general
Electrical
component
locations
general
information
610-1
auxíliary
relay
panel
610-2
component
location
table
610-9
component
locations
610-3
fuse
position
tables
610-19
fuse
positions
610-1
relay
positions
610-2
splice
panel,
left
610-2
splice
panel,
right
610-3
Electrical
system-general
general
information
600-1
continuity,
checking
600-5
electrical
test
equipment
600-2
safety
precautions
600-1

short
circuits
600-5
short
circuit,
testing
with
ohmmeter
600-6
short
circuit,
testing
with
voltmeter
600-6
troubleshooting
600-3
voltage,
measuring600-4
voltage
and
polarity
600-1
voltage
and
voltage
drops
600-4
voltage
drop,
testing
600-4
wiring
codes
and
abbreviations
600-2
wiring
diagrams
600-2
wiring,
fuses
and
relays
600-1
Electrical
wiring
diagrams
general
information
ELE-1
wiring
diagrams
ELE-2
ABS
ELE-117

ABS/AST
ELE-120
airbag
(supplemental
restraint
system)
ELE-140
air
conditioning
and
heating
ELE-
129
anti-theft
(Alpine)
system
ELE-144
anti-theft
(EWS
II)
ELE-150
body
computer
module
ELE-176
charging
system
ELE-67
convertible
top
ELE-253
cruise
control
ELE-112
data
link
connector
ELE-86
engine
cooling
ELE-94
engine
management
ELE-70
exterior
lights
ELE-194
ground
distribution
ELE-35

headlights/foglights
ELE-180

INDEX
3

Electrical
wiring
diagrams
(cont
.)

heated
seats
ELE-245

horns
ELE-153
instrument
panel
ELE-165
interior
lights/illumination
ELE-211
lumbar
control
ELE-247
on-board
computer
ELE-173
park
ventilation
ELE-139
power
distribution
ELE-2
power
door
locks
ELE-226
power
mirrors
ELE-241
power
seats
ELE-243

power
sunroof
ELE-248

power
windows
ELE-231
radio/cassette/CD/speakers
ELE-
255
rear
window
defogger
ELE-160
shift
interlock
ELE-110
starting
ELE-63
transmission
electronics
ELE-96
warning
systems`
.
chimes
ELE-178
wiper/washer
ELE-154
Emergencies
See
Fundamentals
for
the
do-it-
yourself
owner
Engine-general
general
information
100-1
air
flow
measurement
and
vacuum
leaks
100-12
basic
engine
settings
100-11
basic
requirements
100-11
battery
voltage
100-12connecting
rods
and
pistons
100-1
cooling
system
100-5
cylinder
block
and
crankshaft100-1
cylinder
compression,
checking
100-6
cylinder
head
and
valvetrain
100-2
DISA
(dual
resonance
intake
system)
100-3,130-3
driveability
troubleshooting
100-8
engine
management
system
100-3
fuel
delivery
100-5
fuel
supply
100-14ground
connections
100-13
ignition
100-5
lubrication
system100-5
mechanical
troubleshooting
100-5
on-board
diagnostics
(OBD)
100-8
oxygen
sensors
100-11
preventive
maintenance
100-11
VANOS
(variable
valve
timing)
100-2warningsand
cautions
100-5
wiring
andharness
connections100-
13Engine
control
module
(ECM)
See
Fuel
injection
Engine
removal
and
installation
general
information
110-1
engine,
removing/installing(4-cylinder
engines)
110-1
engine,
removing/installing
(6-cylinder
engines)
110-4
Engine
coolant
temperature
(ECT)
sensor
See
Fuel
injection
Engine
hood
See
Fenders,
enginehood

8
INDEX

Speakers
See
Radio
SRS
(Supplemental
restraint
system)
See
Airbag
system
(SRS)
Starter
See
Battery,
starter,
alternator
Steering
and
wheel
alignment
general
information
320-1
caster
and
camber
320-5
front
toe-in
and
toe
difference
angle
320-6
outer
tie
rod
end,
replacing
320-4
power
steering
pump,
removing/
installing
320-2
power
steering
system
320-2
power
steering
system,
bleeding/filling
320-3
rear
toe-in
320-6
steering
gear320-3
steering
gear
rack,
removing/installing
320-3
steering
wheel
320-1
steering
wheel,
removing/installing
320-1
tie
rod,
replacing
320-5
wheel
alignment
320-5
wheel
alignment
specifications
320-6
Steering
gear
See
steering
and
wheel
alignment
Strut
See
Front
suspension
Subframe
See
Front
suspension
Sunroof
general
information
540-1
motor,
removing/installing
540-3
panel,
adjusting
540-2
panel,
emergency
closing
540-2
Suspension,
front
See
Front
suspension
Suspension,
rear
See
Rear
suspension
Suspension,
steering
and
brakes
general
information
300-1
al¡
season
traction
(AST)
300-4
antilock
brake
system
(ABS)
300-2
brakes
300-2
front
suspension
300-1
integrated
systems
300-2
M3
suspension
and
brakes
300-7
steering
300-2
rear
suspension
300-2suspension
and
steering
troubleshooting
300-7
tires
and
wheels300-2

T

Switches
and
electrical
accessories
general
information
612-1
dome
light,
rear
map
lights,
trunk
light,
replacing
bulbs
612-7
hazard
warning
switch,
replacing
612-5
headlight
switch,
replacing
612-5
foglight
switch,
replacing
612-5
ignition
electrical
switch,
replacing
612-3
ignition
lock
cylinder,
replacing
612-4
ignition
switch
assembly
612-3
outside
mirror
switch,
replacing
612-6
power
window
switch,
replacing
612-5
turn
signal
switch
and
wiper
switch,
removing/installing
612-1
wiper
switch
See
turn
signal
and
wiper
switch

Taillight
See
Exterior
lighting
Thermostat
See
Cooling
system
Throttleposition
sensor
(TPS)
See
Fuel
injection
Throw-out
bearing
See
ClutchTierod
See
Steering
and
wheel
alignment
Tires
See
Suspension,
steering
and
brakes-general
See
also
Maintenance
program
Timing
chain
See
Camshaft
timing
chain
Toe-in

See
Steering
and
wheel
alignment
Tools
See
Fundamentals
for
the
do-it-
yourself
owner
Torque
convector
See
Automatic
transmission
Towing
See
Fundamentals
for
the
do-it-
yourself
owner
Traction
control
See
also
Suspension,
steering
and
brakes-general
Trailing
arm
See
Rear
suspension
Transmission-general
See
also
Automatic
transmission
See
also
Manual
transmission
general
information
200-1
automatic
transmission
200-1
manual
transmission
200-1
transmission
ID
codes
200-2
Transmission
fluid
See
Maintenance
program
See
also
Automatic
transmission
Transmission
input
shaft
See
Manual
transmission
Transmission
output
shaft
See
Manual
transmission

Trim,
interior
See
Interior
trim
Trunk
lid
general
information
412-1
trunk
lid,
412-1
trunk
lid,
aligning
412-1
trunk
lid,
removing/installing
412-1
trunk
lid
support
strut,
removing/
installing
412-2

U

Upholstery
See
Maintenance
program
U-joints
See
Driveshaft

V

V-belt
See
Maintenance
program
Vacuum
booster
See
Brakes
Vacuum
leaks
See
Engine-general
Valveguides
See
Cylinder
head
and
valvetrain
Valve
seals
See
Cylinder
head
and
valvetrain
Valveseats
See
Cylinder
head
and
valvetrain
Valves
See
Cylinder
head
and
valvetrain
Valvetrain
See
Cylinder
head
and
valvetrain
VANOS
(variable
valve
timing)
See
Camshaft
timing
chaín
See
also
Engine-general
Vehicle
identification
number
(VIN)
See
Fundamentals
for
the
do-it-
yourself
owner
Vehicle
speed
sensor
See
Instruments
Ventilation
See
Air
conditioning
See
also
Heating

Voltage
regulator
See
Battery,
starter,
alternator
Voltage
tests
See
Electrical
system-general

W

Warnings
vi¡
Washer
fluid
pump
See
Wipers
and
washers
Washers
See
Wipers
and
washers
Water
pump
See
Cooling
system
Waxing
See
Maintenance
program