1997 BMW 328i AC mounting

121-
6



BATTERY
STARTER,
ALTERNATOR

Alternator,
removing
and
installing

(6-cylinder
engine)

A
replacement
alternator
should
have
the
same
rating
as

the
original
.
Alternator
manufacturer
and
ampere
rating
are

normally
marked
on
the
alternator
housing
.

1
.
Disconnect
negative
(-)
battery
cable
.

CAUTION-

Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
viii
.

2
.
Remove
alternator
cooling
duct
and
air
filter
housing

assembly
from
car
.
Disconnect
wiring
from
rear
of
alter-

nator
.

3
.
Remove
radiator
cooling
fan
and
fan
shroud
.
See
170

Radiator
and
Cooling
System
.

4
.
Remove
alternator
drive
belt
from
alternator
pulley
.
On

engines
with
hydraulic
belt
tensioner,
remove
tensioner

idler
pulley
(upper
roller)
from
alternator
bracket
.
See

Fig
.
5
.

ALTERNATOR
SERVICE

Fig
.
5
.



Pry
off
cover
from
tensioner
and
then
lever
tensioner
clock-
wise
to
release
belt
tension
.
Remove
upper
roller
(A)
once
belt
ís
removed
.

NOTE-

If
reusing
drive
belt,
mark
direction
of
rotation
on
belt

before
removing
.

5
.
Remove
upper
and
lower
mounting
bolts
and
lift
out
al-

ternator
.

6
.
Installation
is
reverse
of
removal
.
Note
locating
notches
on
tensioner
idler
pulley
(upper
roller)
alternator
brack-

et
when
installing
pulley
.

Tightening
Torques

"
D+
wire
to
alternator
(M6
nut)
.......
7
Nm
(53
in-lb)

"
B+
wireto
alternator
(M8
nut)
.......
13
Nm
(10
ft-Ib)

"
Pulley
to
alternator
(M16
nut)
.......
60
Nm
(44
ft-Ib)

Voltage
regulator,
removing
and
installing

1
.
Disconnect
negative
(-)
cable
from
battery
.

NOTE-



2
.
Remove
alternator
as
described
earlier
.

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



3
.
Remove
cooling
duct
from
rear
of
alternator
.
See
Fig
.
6
.

Alternator

.
.g-



p~
J

-..
.

Fig
.
6
.



Alternator
assemblyand
related
parts
.

Cooling
duct

0012524

4
.
Remove
voltage
regulator
mounting
screws
and
re-

move
regulator
from
alternator
.

5
.
Installation
is
reverse
of
removal
.
Clean
brush
contact

surfaces
in
alternator
and
check
brush
length
asde-

scribed
later
.

121-1
O



BATTERY,
STARTER,
ALTERNATOR

9
.
Remove
starter
from
above
.

10
.
Check
starter
pinion
gear
and
flywheel
teeth
for
dam-
age
.

11
.
Installation
is
reverse
of
removal
.

Tightening
Torques

"
tntakemanifold
to
cylinder
head

M7
nut
...
.
................
...
.
15
Nm
(11
ft-Ib)

M8
nut/bolt
.............
.
.
..
...
22
Nm
(16
ft-Ib)

"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-Ib)

"
Support
bracket
to
starter
(M5
nut)
...
5
Nm
(44
in-lb)

"
Support
bracket

to
engine
block
(M10
bolt)
.
.
..
..
...
47
Nm
(35
ft-Ib)

"
Wire
toterminal
50
(M6
nut)
.
..
.....
6
Nm
(53
in-lb)

"
Wire
toterminal
30
(M8
nut)
...
.....
12
Nm
(9
ft-Ib)

Solenoid
switch,
removing
and
installing

1
.
Remove
starter
as
described
above
.
Tightening
Torque

2
.
Remove
cover
from
solenoid
switch
.



"
Field
winding
strap
to
starter
(M8)
...
.
12
Nm
(9
ft-Ib)

3
.
Disconnect
fieid
winding
strap
between
starter
motor

and
solenoid
switch
.

NOTE-

The
condition
of
the
field
winding
strap
is
critical
.
If
it
is
damaged,
bumed
or
partially
melted
through,
a
new
or

rebuilt
starter
motor
is
needed
.

4
.
Remove
solenoidswitch
mounting
screws,
and
sepa-

,
rate
solenoid
from
starter
.
See
Fig
.
12
.

CAUTION-

When
installing
fieid
winding
strap
to
starter,
posi-

tion
it
so
that
it
does
not
contact
the
starter
body
.

STARTER
SERVICE

131~184

Fig
.
12
.
Starter
solenoid
mounting
screws
(arrows)
are
tight
.
Use
en
impact
screwdriver
to
loosen
the
screws
.

5
.
Installation
is
reverse
of
removal
.
Lubricate
solenoid
pistos
with
light
grease
.

6
.
Remove
fuel
rail
mounting
bolts
.
See
Fig
.
17
.

0012504

Fig
.
17
.
Location
of
fuel
rail
mounting
bolts
(A)
and
fuel
inlet
and
return
lines
(B)
on
M44
engine
.
Upper
manifold
has
been
removed
.

7
.
Pull
upon
fuel
rail
and
remove
injector
rail
with
injec-tors
.
Remove
individualinjectors
by
removing
injector

retaining
clip
and
pullinginjector
from
rail
.
See
Fig
.
18
.

Fig
.
18
.
Pry
retaining
clip
from
injector
(1),
then
pull
injector
from
rail
(2)
.

8
.
Installation
is
reverse
of
removal
.

Tightening
Torque

"
Fuel
rail
to
cylinder
head
..
.
..
..
...
10
Nm
(89
in-lb)

FUEL
INJECTION



130-
1
3

Fuel
Pressure
Regulator

The
fuel
pressure
regulator
location
on
E36
models
is

mounted
in
one
of
two
locations
:

Fuel
Pressure
Regulator
Location

"
4-cylinder
engines

1992-
January
1997
............
...
..
on
fuel
rail

January
1997-
on
...............
..
...
under
car

"
6-cylinderengines

1992-1995
.
.
...
...
.
...........
...
..
on
fuel
rail

1996-on
..
.
..
................
...
...
undercar

Fuel
pressure
regulator,
replacing

(fuel
rail
mount)

WARNING
-

Fuel
will
be
discharged
.
Do
not
disconnect
any
wires
that
could
cause
electrícal
sparks
.
Do
not
smoke
or
work
near
heaters
or
other
fire
hazards
.
Keepan
approved
fire
extinguisher
handy
.

9
.
On
6-cylinder
engines,
remove
top
engine
covers
.
Re-
move
fuel
rail
mounting
bolts
and
lift
up
fuel
rail
.

1
.
Disconnect
vacuum
hose
from
fuel
pressure
regulator
.

See
Fig
.
19
.

"
Fit
new
O-rings
when
installing
injectors
.
For
ease
of

installation,
lightly
lubricate
O-rings
with
SAE
90
or



0012732

equivalent
lubricant
.



Fig
.
19
.
Fuel
pressure
regulator
(arrow)
on
M42
engine
.
Vacuum
hose

"
Check
that
injector
electrical
connections
are
correctly



shown
at
A
.

fitted
and
that
injectors
are
fully
seated
prior
to
install-

ing
fuel
rail
mounting
bolts
.



2
.
Remove
bolt
from
regulator
clamp
.
Remove
clamp
.
Note

"
Replace
wire
ties
.



installed
direction
of
regulator
to
fuel
rail
.

3
.
Wrap
a
shop
rag
around
regulator,
then
remove
regula-

tor
from
fuel
rail
by
pulling
straight
out
.

FUELDELIVERYTESTS

u0
I
.[
Ia

Fig
.
21
.
Air
flow
sensor
harness
connector
terminal
identification
.

4
.
Replacing
air
flow
sensor
:

"
Remove
large
band
clamp
attaching
air
boot
to
sensor
.

"
Remove
airfiltertop
cover,
then
remove
airflow
sensor

mounting
nuts
inside
cover
.

"
Reconnect
air
boot
and
harness
connector
.

Engine
coolant
temperature
(ECT)
sensor,

testing
and
replacing

The
engine
coolant
temperature
(ECT)
sensor
sends
con-

tinuous
engine
coolant
temperature
information
to
the
ECM
.

As
temperature
increases,
sensor
resistance
decreases
.

"
With
harness
connector
disconnected,
check
resis-

tance
across
sensor
terminals
.

"
Compare
tests
results
to
values
in
Table
d
.

FUEL
INJECTION



130-
1
5

0011984

Fig
.
22
.
M42
engine
coolant
temperature
(ECG
sensor
(arrow)
.

Table
d
.
Engine
Coolant
Temperature
Sensoror

Intake
Air
TemperatureSensor
Test
Values

(DME
1
.7)

Test
temperatures



Resistance
(k
ohms)
',

14±2°F(-10t1°C)



7-11
.6

68±2°F
(20
t
1
°C)



2
.1
-2
.9

176
±
2°F
(80
t
V
C)



0
.27-0
.40

The
ECT
sensor
is
located
under
number
one
intake
run-



'

ner
.
See
Fig
.
22
.
NOTE-

1
.
Check
ECM
referente
voltage
to
sensor
:



The
test
values
listed
represent
only
three
test
points
from
a
continuous
resistance
NTC
sensor
.
Check
the
"
Disconnect
harness
connectorfrom
ECT
sensor
.



full
linear
response
to
increasing
temperature
as
the
"
Turn
ignition
key
on
.



engine
warms
up
.
"
Check
for
5
volts
between
supply
voltage
(brown/red)

wire
of
harness
connector
and
ground
.



3
.
If
ECT
sensor
fails
these
tests,
it
is
faulty
and
should
be

"
Turn
ignition
key
off
.



replaced
.
If
no
faults
are
found,
reconnect
electrical
"
If
voltage
is
not
present
or
incorrect,
check
wring
from



harness
.

ECM
and
check
ECT
sensor
reference
voltage
output

at
ECM
.
See
Table
h
.
NOTE-

2
.
Check
ECT
sensor
resistance
:



Use
a
new
copper
sealing
washer
when
installing
sen-
sor
.
Reptace
any
lost
coolant
.

WARNING
-

Do
not
replace
the
ECT
sensor
unlessthe
engine
is

cold
.
Hot
coolant
can
scald
.

Tightening
Torque

"
ECT
sensor
to
cylinder
head
.....
..
13
Nm
(10
ft-Ib)

BOSCH
DME
M1
.7
COMPONENT
TESTS
AND
REPAIRS

001ía4
i

Fig
.
34
.
Intake
air
temperature
(IAT)
sensor
in
top
section
of
air
filter
housing
.

¡die
speed
control
valve,
replacing

side
of
the
throttle
body
.
See
Fig
.
35
.

1
.
Disconnect
harness
connector
from
¡die
valve
.

0012725

Fig
.
35
.
M44
engine
:
Throttle
housing
showing
(A)
throttle
position
sensor
(fPS)
and
(B)
¡die
speed
control
valve
.

2
.
Remove
twomountingscrews
holding
sensor
to
throttle

housing
.

The
¡die
speed
valve
on
the
M44
engine
is
located
on
the

FUEL
INJECTION



130-23

2
.
Disconnect
vacuum
hose
and
retaining
screws
.

3
.
Pull
¡die
speed
control
valve
from
its
fittings
.

4
.
Installation
is
reverse
of
rémoval
.
Always
replace
0-

rings
and
seals
.

NOTE

Poor
driveability
may
be
notíced
after
installing
a
re-
placement
¡dio
control
valve
.
After
about10
minutes
of
driving,
the
idie
speed
should
retum
to
normal
.

SIEMENS
MS
41
.1

COMPONENT
REPLACEMENT

On-Board
Diagnostics
II
(OBD
II)
is
incorporated
into
the
Si-

emens
MS
41
.1
engine
management
systems
used
in
the

M52
and
S52US
engine
.
Refer
to
Fig
.
36
.

OBD
11
is
capable
of
detecting
a
fui¡
range
offaults
.
When

faults
are
detected,
a
Diagnostic
Trouble
Code
(DTC)
is

stored
in
the
system
ECM
.
The
Check
Engine
warning
light
will
also
come
on
if
an
emissions-related
fault
is
detected
.
The

most
efficient
way
to
diagnose
the
Siemens
OBD
II
system
is

by
using
a
specialized
scan
tool
.
The
OBD
II
system
is
capa-

ble
of
storing
hundreds
of
faults,
making
diagnostics
with
a
scan
tool
the
only
viable
method
.
Therefore,
system
diagnos-

tics
is
not
covered
here
.

NOTE
-

"
The
OBD
11
fault
memory
(including
an
illuminated

Check
Engine
light)
can
only
be
reset
using
the
spe-
cial
scan
tool
.
Removing
the
connector
from
the
ECM
or
disconnecting
the
battery
will
not
erase
the
fault
memory
.

"
The
16-pin
OBD
11
diagnostic
connector
is
located
on

the
lower
left
dash
panel
.
Refer
to
Fig
.
1
.

"
BMW
special
scan
tool
ora
"generic"
OBD
11scan
tool

must
be
used
to
access
DTCs
.
3
.
Installation
is
reverse
of
removal
.
No
adjustment
is
nec
essary
.



"
Table
1
lists
engine
control
module
(ECM)
pinouts
forthe
MS
41
.1
systems
.

SIEMENS
MS
41
.
1
COMPONENT
REPLACEMENT

130-26



FUEL
INJECTION

Throttle
position
sensor
(TPS),
replacing

The
throttie
position
sensor
is
located
on
the
side
of
the
throttie
housing
.
See
Fig
.
40
.

Fig
.
40
.
M52
engine
:
Throttle
position
sensor
(arrow)
.

1
.
Unplug
harness
connector
from
sensor
.

NOTE
-

On
cars
with
tractioncontrol,
do
not
confuse
the
throttieposition
sensor
on
the
main
throttie
body
wíth
the
throt-
tie
position
switch
on
the
secondary
throttie
body,
where
applicable
.

3
.
Installation
is
reverse
of
removal
.

¡die
speed
control
valve,
replacing

0012700b

The
¡die
speed
control
valve
is
mounted
on
the
underside
of
the
intake
manifoldadjacent
to
the
dipstick
tube
bracket
.
Ac-
cessing
the
valve
is
best
accomplished
by
first
removing
the
throttie
housing
.

1
.
Disconnect
intake
air
bootfrom
throttie
housing
.
Unbolt
throttie
body
and
¡ay
aside
.
(Do
not
disconnect
throttie
cable
or
electrical
harness
connectors
to
throttie
body
.)

2
.
Unbolt
dipstick
tube
bracket
from
intakemanifold
.

3
.
Workíng
under
intake
manifold,
disconnect
electrical
harness
connector
from
¡die
speed
control
valve
.

4
.
Remove
two
bolts
retaining
¡die
speed
control
valve
to
underside
of
intake
manifold
.
Remove
valve
from
intake
manifold
.
Remove
hose
clamp
and
disconnect
hose
.

ECM
PIN
ASSIGNMENTS

mately
one
minute
.

Vacuum
seal

Mounting
bracket

Electrical
connector

0013185

Fig
.
41
.
M52
engine
:
¡die
speed
control
valve
(located
under
intake
manifold)
.

5
.
Installation
ís
reverse
of
removal
.
Use
new
gaskets
when
installing
.

NOTE
-

Poor
driveabilíty
may
be
noticed
atter
installing
a
re-
placement
idle
speed
control
valve
.
After
about
10
min-utes
of
dríving
the
idle
speed
should
return
to
normal
.

ECM
PIN
ASSIGNMENTS

2
.
Remove
twomountingscrews
holding
sensor
to
throttie
housing
.



Engine
control
module
(ECM),
accessing

1
.
Disconnect
negative
(-)
battery
cable
.
Wait
approxi-

CAUTION-

Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
vüi
.

2
.
Remove
engine
control
module
(ECM)
compartment
cover
from
right
side
of
engine
compartment
rear
bulk-
head
.
Cover
is
retained
withfour
captíve
screws
.
See
Fig
.
42
.

3
.
Disconnect
control
module
harness
connector
by
re-
leasing
fastener
and
pivoting
connectorup
and
off
ECM
.

4
.
Remove
ECM
from
retaining
brackets
and
pull
ECM
from
its
holder
.

5
.
Installation
is
reverse
of
removal
.

160-
4



FUEL
TANK
AND
FUEL
PUMP

Fig
.
4
.



Pinch
off
supply
and
retum
fuel
hoses
(arrows)
before
dis-
connecting
from
rigid
metal
lines
.

0013143

Fig
.
5
.
After
removing
exhaustsystem,
remove
heat
shield
screws
(arrows)
and
heat
shield
.

9
.
Working
underneath
car,
loosen
hose
clamp
and
dis-

connect
filler
hose
.

10
.
Support
tank
from
below
.
Remove
tank
strap
mounting

bolts
.
Lower
and
remove
tank,
disconnecting
right
side



TheE36
model
uses
a
two-lobed
fuel
tank
and
each
lobeof
vent
and
other
hoses/electrical
connectors
as
neces-



the
tank
has
its
own
fuel
level
sending
unit
.
sary
.

11
.
Installation
is
reverse
of
removal
.

"
Always
use
new
seals,
gaskets,
O-rings,
and
hose
clamps
.

"
Inspect
hoses
and
replace
any
that
are
chafed,
dried

outor
cracked
.

"
Inspect
heat
shield
and
replace
if
corroded
.

"
Inspect
rubber
buffers
and
liners
on
fuel
tank,
support
straps
and
on
underside
of
body
.
Replace
rubber

parts
that
are
hardened
or
damaged
.

FUEL
LEVEL
SENDERS

CAUTION-

"
Before
starting
the
engine,
fill
the
fuel
tank
with
at
least
1.5
gallons
(5
liters)
of
fuel
to
prevent

damaging
a
dry
fuel
pump
.

"
If
the
filler
neck
has
been
removed
from
the
body,
be
sure
toreattach
theneck's
grounding
screw
(where
applicable)
.
Check
electrical
resistance
between
the
ground
tab
and
wheel
hub
.
The
re-
sistance
shouldbeno
higher
than
0
.6
ohms
.

Tightening
Torques

"
Fuel
tank
to
body
.............
...
23
Nm
(17
ft-Ib)

"
Hose
clamps
(10
mm-16
mm
día
.)
..
2
.0
Nm
(18
in-lb)

Fuel
Tank
Evaporative
Control
System

The
fuel
tank
evaporative
control
system
is
used
to
vent
the

fuel
tank
to
a
charcoal
canister,
which
is
then
purgedby
en-

gine
vacuum
during
normal
engine
operatíon
.
This
controls

emission
of
raw
hydrocarbons
(fuel)
to
the
atmosphere
.
See

Fig
.
1
.

A
fuel
expansion
tank,
located
under
the
right
rear
fender,

traps
overflow
fuel
and
incorporates
extra
fuel
tank
plumbing
.

Startingwith
1996
models,
OBD
II
standards
require
that

the
fuel
tank
evaporative
control
system
be
monitored
for

leaks
.
This
is
accomplished
usingthe
fuel
tankpressuresen-

sor,
the
ventshut
off
valve,
and
the
evaporative
purge
valve
.

NOTE-

On
most
early
cars(1992-1995),
the
charcoal
canister

is
in
the
engine
compartment
.
On
latercars,
the
char-
coal
canister
is
under
the
spare
tire
in
the
luggage
com-
partment
.

FUEL
LEVEL
SENDERS

The
right
side
fuel
leve¡
sender
is
integrated
with
the
fuel

pump
.
Each
senderhas
a
float
connected
to
a
variable
resis-

tance
for
fuel
leve¡
.
When
replacing
the
sender/pump
assem-

bly
always
replace
hose
clamps,gaskets
and
O-rings
.

WARNING
-

When
removing
the
fuel
level
sender
or
the
fuel
pump,
the
fuel
tank
should
be
emptied
.

Fuel
leve¡
senders,
testing



Fuel
leve¡
sender
(right
side)

The
left
and
right
fuelleve¡
sending
units
are
wired
in
series
.



and
fuel
pump,
removing
and
installing

The
fuel
gauge
receives
a
signal
that
is
the
average
of
the
two



1
.
Disconnect
negative
(-)
cable
from
battery
.

input
values
.

1
.
Remove
rear
seat
cushion,
lift
up
insulation
mats,
andremove
both
fuel
tank
access
covers
.

2
.
Disconnect
white
plug
on
each
sending
unit
.
See
Fig
.
6
.

3
.
Check
resistance
value
of
eachsending
unit
.
Values
should
be
the
same
.

5
.
If
valuesare
different,
remove
sending
units
as
described

below,
and
check
resistance
valuésacross
terminals
.
Table
a

lists
resistance
values
for
senders
at
various
float
positions
.

Table
a
.
Fuel
Leve¡
Sender
Resistances

Float
position



Test
result
(ohms)

Right
side
empty



10
ohm
t2

Right
side
full



250
ohm
±
5
Left
side
empty



10
ohm
t
2

Left
side
fui¡



250
ohm
±
5

FUEL
TANK
AND
FUEL
PUMP



160-
5

CAUTION
-

Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautionsglven
at
the
front
of
this
manual
onpage
viii
.

2
.
Drain
fuel
from
tank
as
described
earlier
.

WARNING
-

Always
unscrew
the
fuel
tank
cap
to
release
pres-
sure
in
the
tank
before
working
on
the
tank
or
fines
.

3
.
Remove
rear
seat
cushion
and
pull
back
insulation
pad
under
right
side
.

4
.
Remove
screws
holding
rightfuel
tank
accesscover
.

Remove
cover
.

5
.
Label
fuel
hoses
.
Disconnect
hoses
and
harness
con-

nectors
from
fuel
sending
unit
and
fuel
pump
.

6
.
Unscrew
threaded
collar
from
fuel
pumplfuel
leve¡
sender
.
Slowly
withdraw
assembly
from
tank,allowing

fuelto
drain
off
.
See
Fig
.
7
.
0013187
&
0013194

Fig
.
6
.



Fuel
pump/leve¡
sender
terminal
identification
.
Check
resis-
tance
at
terminals
of
white
connectors
(arrows)
.



"
If
necessary,
push
leve¡
sender
arm
toward
fuel
pump

assembly
to
facilitate
removal
.

NOTE
-

BMW
special
tool
no
.
16
1
020
should
beused
to
re-
move
and
install
the
threaded
collar
.
Damage
to
the
collar
may
result
if
the
special
tool
is
not
used

WARNING
-

NOTE-



Fuel
may
be
spilled
.
Do
not
smoke
or
work
near

The
compensating
siphon
pump
(Fig
.
1)
maintains
the



heaters
or
other
fire
hazards
.

fuel
leve¡
between
the
right
and
left
tank
lobes
.
If
the
re-
sistances
are
different
between
the
left
and
right
send-
ers,
remove
the
senders
and
visually
inspect
the
leve)
in



7
.
Using
a
new
sealing
ring,
install
pump
and
sending
each
lobe
.
If
the
leve¡
is
different,
check
the
siphon
com-



unit,
being
sure
that
fuel
line
connections
point
in
same

pensating
pump
.



direction
as
they
carne
out
.

8
.
Reconnect
harnessconnector
and
hoses
.
Fill
tank
and

check
for
leaks
by
running
engine
.
Insta¡¡
access
cover

and
its
mountingscrews
.
Reconnect
negative
(-)
cable

to
battery
.

CAUTION
-

Before
starting
the
engine,
fill
the
fuel
tank
with
at
least
1
.5
gallons
(5liters)
of
fuel
.
The
pump
will
be
damaged
if
you
run
it
without
fuel
.

FUEL
LEVEL
SENDERS