BMW M6 Torque Specs

I I LN6IN€

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t7 f<M r(!t-tt(.-

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37 J N r"tr-{ r?r?laT\ Sr,t \?t)u S i qt) s.r S

1 t L7; A'/

5 t bofi7 rQrr il.

L | GeufRrtu r-(Cci . sys,

6 Z 14 =;fT(ut .r/L E z-r r 1-5

6'5 Lr ( nTS

b 7 trcftrv( X tl c-

bf TKfr{ \ ia b s(e<'rr t \ - kt tu i l : /

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001

Area (squars meterl

Volume (cubic meterl

Angle (degree. radian)

Mass (kilograml

Density (kilogram per cubic meterl

Time (secondl

Frequengy

Revolutions (speedl

Velocity

Acceleration

Force (Neurtonl

Pressure (Pascall

1 kg/m3 = 0.001 kg/dm3

l min=60s

1Hz=l/s

1 U/min = l /min 1/min = 1/60 s

1 m/s = 3.6 km/h

1N=lkgm/s2 1kp=9.81 N

1 at = 1 kp/cm2 = 0.981 bar = 98 066.5 Pa1 m WS = 9 806.65 Pa = 9 806.65 N/m21 Torr = 1.333 224 mbar1 mm Hg = 133.322Pa = 133.322 N/m21N/m2=1Pa1 kg/mm2 = 9.81 N/mm2

MAINTENANCE AND GENERAL DATA

CONVERSION AND COMPARISON TABLE OF.STATUTORY MEASUREMENT UNITS

Measurement/Value Conversion or Equivelant

Length (meterl 1m=1O00mm

1m2= 106 mm2 1 mm2 = 0.01 cm2

I m3 = 106 cm3 I dm3 = 0.001 m3

1 rad = 1**k -

s7o

lkg=10009

lkm=1000m 1 Fm = 0.001 mm

10=r/180rad

1g=1000m9 1t=1Mg=1000k9

lkg/dm3=1kg/ l

t h=60min

I

-JF-* '

MAINTENANCE AND GENEBAL DATA

CONVERSION AND COMPARISON TABLE OF STATUTORY MEASUREMENT UNITS

Measurement/Value Conversion or Equivelant

Mechanical load 1N/m2=1Pa

Energy, work, thermalvolume (Joule)

Torque (Newton msterl

Power (watt)

Viscosity - dynamic

- kinematic

Tempsrature (Celsiusl(Kelvin)

Electrical current (amperesl

Electrical voltage (voltl

Electrical rssistance (ohml

Magnetic flux (Weber)

Magnetic flux density (Teslal

Magnetic field strengnh

1 kp/mm2 = 9.81 N/mm2

1J=1Nm 1 kwh = 3.6 MJ 1 kpm = 9.81 1 cal = 4.1868 J

1 kpm = 9.81 Nm

1 kW=1000W 1 W=1 Nm/s=1 J/s 1 PS=736W=7bkpm/s

lPas=1Ns/m2 1P=0.1 Pas=1g/cms

1 mzls = 1 pas (m3/t<gl I St = 1 cm2ls = 0.0001 m2ls

ooc = 213.15 R1 grd = loK = 1 K = loC (temperature differencel

1 mA = 0.001 A lkA=1000A

1V=1WA 1 mV = 0.001 V 1MV=lOOV

lohm=1V/A=1/S

1Wb=1Vs 1M=10'8Wb

1T=1! lb/m2

Light strengnh (Candela)

1A/m=1N/Wb

STANDARD TIGHTENING TOROUE VALUES

Applicable only to bolts with standard and fine metric threadsaccording to DIN 13, sheet 13, and nuts with a nut height of0.8 x d according to DIN 934 and exclusively for total micron= O,125 (bolts phosphate treated, nuts without final treatmentor galvanized; lubricated condition: either non-lubricated orlubricated with oill.

For cadmium plated bolts or nuts (total micron ̂ r 0.08 to 0.091the tightening torque must be approximately 30 % less than inthe table.

Not applicable when another surface or lubricated condition ofthe threads is used or if thera is a variation in the nut height.

Not applicable to bolts with expansion shanks, self-locking boltsor nuts as well as connections for parts made of different mater-ials.

The values stipulated in the table apply to screwed connestionswhich correspond to the above conditions.

00-A1

Extraction from BMW Plant Standard N 600 02.0, }, r , ,

.t.

'N,

Threads

Max. Tightening Torque Msp (Nml

Property Class According to DIN 267

5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9

M4 1.3 1.8 1.6 2.1 2.4 2.9 4.1 4.9M5 2.7 3.6 3.2 4.3 4.8 5.9 8.3 10.0M6 4.7 6.2 5.6 7.5 8.4 9.9 14.0 16.5M8 11 15 14 18 20 24 34 40M8x1 12 16 14.5 19.s22 26 36 44M10 23 30 27 36 40 47 66 79M10xl 25 34 30 40 46 54 75 91M12 39 52 47 62.5 70 82 115 140M12x1.5 41 54.5 49 65.5 73.5 87 123 147M14 62 82.5 74.5 99 110 130 180 220M 14x 1.567 89.5 80.5 107 120 143 200 240M16 94.5 126 113 150 170 200 280 3rrcM16x1.5 101 135 121 162 182 216 303 364M18 130 174 166 209 235 280 390 470

M18x1.5 147 195 176 234 264 313 440 527M20 184 245 220 295 330 390 550 660M20x1.5 204 272 245 326 367 435 612 734

tI

'4

ENGINE M 10

Page

Engine in generat . .11. . . 1Fuel consumption. 2Oil consumption. ICrankcase 11Cylinder head . 12Valvegiudes . : . . . 12Valve seat inserts 13Crankshaftandbear ings.. . . 14t ly* l tg" l . : . . . 17Vibration damperConnecting rods and bearings 18Pistons. 19Piston rings . 20Camshaft. 21

21Chain tensioner piston. )Rocker arms . 21Valves 22Oil supply 239!! p.t,tp.Oilf i l ter 25Water pump. 25

26Fancoupl ing. . . . . . . . . . :Thermostat 26

2,

11

11 00

11 1111 12

1212

11 2111 2211 2311 2411 25

2511 31

3111 3311 3411 4011 4111 4211 5111 5211 53tu

3

11 ENGINE M 20

Page

Engine in general . . 11 --3011 00

11 1111 12

1212

11 2111 2211 2311 2411 25

2511 3111 3311 3411 4011 4111 4211 5111 5211 53

FuelconsumptionOilconsumption .CrankcaseCylinder head .Valve guidesValve seat insertsCrankshaft and bearings . . . .FlywheelVibration damperConnecting rods and bearingsPistonsPiston rings.CamshaftRocker arms .ValvesOilsupplyOil pumpOilf i l terWater pumpFancoupl ing . . .Thermostat

313941424243444747484950515152535455555656

4

11 ENGINE M21

Page

Engine in general 11 -7OFuelconsumption -71Oil consumption. -79Crankcase - 80Cyl inderhead. -81Valve guides - 81Valveseats . -83Burners - 83Crankshaftandbear ings . . . . . . . : -84Ffywheel -87Vibration damper - 87Connecting rods and bearings - 88Pistons - 89Pistonr ings. -90Camshaft - 91Vafves - 92Oil supply - 93Oil pump

11 00

31344041515253616591

1112

2122232425

Water pumpFan clutchThermostat - 97

-95-96

-97-97-97

Charging pressure blowoff valveTurbocharger .. .Vacuum pump

1,

q

$."

T- ' t

11 00

11 ENGINE M 30

Engine in generalFuelconsumptionOil consumption..

11 11 Crankcase11 12 Cylinder head . . . .

12 Valve guides12 Valve seat inserts

11 21 Crankshaft and bearings . . . .11 22 Flywheel11 23 Vibration damper11 24 Connecting rods and bearings11 25 Pistons

25 Pistonr ings. . ' . . . . .11 31 Camshaft

31 Chain tensioner piston11 33 Rocker arms .

Page

11--.3013023(x,310311311312313319319320321322323323323

I

6

11

11 3411 N11 4111 4211 5111 5211 53

ENGINE M 30

ValvesOil suppfyOil pumpOil filterWater pumpFancoupl ing . . .Thermostat

Page

11 - 32432532632732832s330

I. ,t

11 ENGINE

S 14 = 4 Cyl. M-Power EngineS 38 = 6 Cyl. M-Pswer En{ine

Engine in generalFuelconsumptionOil consumption .GrankcaseCylinder head .Valve guidesValve seat inssrtsValve seats .Timing caseCrankshaft and bearingFlywheelVibration damperConnecting rods and bearingsPistonsPiston rings .GamshaftChain tonsionerValvesOil supplyOil pumpFan clutchThermostat . . . .

11 00

11 1111 1211 1211 1211 1211 1211 2111 2211 2311 2411 2511 2511 3111 3111 3411 4011 4111 5211 53

11 . . . 800801802803804804805806807808813813814815816817818819820820821821

I

I

,(

ENGINE M 1O

11 - 1

818

318i/A

1983 Model

11 00 ... Erqine in General

Bore mm (in. l 89 (3.5041

Stroke mm (in.l 71 l2.7e5l

Displacement, effectiva cm3 (in.3l 1766 (107.8)

Compression ratio 93:1

Max. power output.o DIN 70020 KW (hpl

at engine speed rpm

75 (1011

5800

Max. engine speed rpm 6300

Max. torque Nm (ft lbsl

atenginerp*Off

1/00 (1031

4500

Compression pressure (approxi-mately equal value for allcylinders) bar {psil 10.. . 11'1142.. . 1561

ENGINE M 10 818

318 i/A

1984/1985 Modets

11 00 ... Engine in General

89 {3.504)

Displacement, effoctivo cm3 (in.3l 1766 (107.81

Compression ratio

Max. porarcr output to DIN 70020 KW (hpl

at engine speed

Max. engine speed

Max. torque Nm (ft. tbs.)

at engine speed rpm

Compression pressure(approx. equal value for allcylindenl Uar (psil 10 ... 11 1142... 1561

q

\J

ENGINE M 10

11 -2

318 i 318 i/A

1983 Models

FuelconsumptionciV mpg

Highway mpg

Composite (SS % city and45 % highwayl mps

27.2 26.6

37.9 33.6

31.2 29.4

1984 Modclr

Fuet coniumptioncitv mps I zs.t I zs.s IHishway mps | 36.6 | go.o Icompcits {Es % city and | | |its % hishway) mps l2e.s I zt.s I

1985 Modolr

l-u.t conrumptioncity mps I zs.t I zu IHishway mps lse.s lsl.+ |Composltl {55 % city and | | |45

'6 hishwayl mps I zs.z I za.s I

fq

ENGINE

DETERMINING OIL CONSUMPTION

Oil consumption meazurements can be made after car has beendriven about 7,500 km or 4,500 miles.This distance is necessary before the oil consumption will havebecome stable.Requirement: engine must not leak oil.

Max. permisible oi lconsumption is 0.15 ltr. / l00 km( 1 quart per 390 milesl.

Accurate consumption values are determined by weighing.Drain engine oil at operating temperature. Allow 5 minutes

' drip time. Weigh and add specified amount of new engine oil.'. Drive car 1,000 km or 600 miles. Drain engine oil at operating

temperature an weigh. Allow 5 minutes drip time. Engine gilspecific gravity at room temperature is appiox. 0.9 kg/6rn3.

Example: added oil - drained oil = consumed oil45009 -36009 =9009

900 : 0.9 = 1000 cc = 1 ltr. per 1000 km

Possible Causes for Excessive Oil Consumption: ,'

1. Engine not broken in fully.2. Valve stem seals damaged.3. Pistons seized.4. Piston rings installed incorrectly, broken or worn.5. Excessive clearance between valve stem and valve giude.

t

ENGINE

11 - 11

11 11 ... Crankcase

CylindersBore dia. -

Standard size

Max. permissible cylinderbore out-of-true

Max. permissible cylinderbore conicity

89,00+0p1 (3.5039+0.00041

89,08+0,01 (3.S071 +0.0004)

8925+0,01 (3.S1 38+0.00041

89,50+0,0 1 (3.S236+0.00041

0,01 (0.00041

0,01 (0.00041

\ -\I

\1

ENGINE M 10

11 -12

818

11 12... Cylinder Head

Cylinder head height(machining limit)

11 12... Valve Guides

mm (in.l 128.6 (5.0631

V.lva guido dis. - bo|t dir. LStandard lizo mm | 14.0 uO - 14.0 M7Ov$tiz61 mm | 14.1 u6 - 14.1 M7Ovtrrizr 2 mm | 14.2 tt6 - 742 MlOwrjzr 3 mm | 143 uB - 14.3 M7

tTobl lmlth mfi linJ I 511.5 (1.9881

Valw guido inrid. dia. I(installodl I

StrId d rlro mm | 8.0 H7OYrrriu. I mm | 8.1 H7

. OwEiz. 2 mm | 4,2 H7

Inrtllir{ tlmp!.rtul! |c] 't indrr h6d oc {oF) l+50(+1221vllwluidc oc (oF)

| - 150 {- 238}

"M 'I

. :\

tq

ENGINE M 10

11-13

Valve seat insert dia. - bore dia.Intake

. . Standard size

-.Qvenire Q.? mmOyqrsize 0.4 mm

818

47.15 96 - 47.00 H7

47.359G -47.2OH747.55sG -47.4OH7

40.15 gG - 40.00 H740.35 s6 - 40.20 H740.55 s6 - 40.40 H7

Exhausl: rStafdafd size

ntbibriiiso.2 mm'Oversize 0,4 mm

mmmmmm

mmmmmm

Installing tomperatureCylinder headValve seat insert

Valve seat angle

Correction angles

Valve seat width (distance "B")Intake and exhaust

Valve seat dia. (distance "M")Intake

+ 50 (+ 122!-- 150 l-2381

45

15175

mm (in.) 1.3 ... 2.0 (0.051 ...0.079)

mm (in.) 44.6 (1.7561

oc (orloc (ofl

11 12... Valve Seat Inserts

Exhaust mm ( in.) 36.6 {1.441}

\ , .

ENGINE M 10

11 -14

818

11 21 ... Grankshaft and Bearings - Double Classification -

Ground sizes of main bearing journalsStandard size red mm (in.l

mm (in.)

mm (in.)

mm (in.)

Undersize 1

ss.oo :3:313 (2.r6s4 :3:3331

ss.oo _ 3:333 tz.ros+

s4.7s- 9'919 l2.isssv-"r - 0.020 t-"-

-.--!trS,rr'ss

- 0.000q- 0.001f

-*"*- 0.000d

- r"mq- 0.0011'

( r . . r , r r , .e rJ Y .

udadBflo?o'S I'red. idilr l i ir/ lq 1116

EXlrsaeI

OA6ta!I6 0'S , .

ffiunidUi$liA3'r '.. red

blue

Radial crankshaft bearing play

mm (in.l

mm (in.)

J

mm (in. l

mm {in.}

mm (in.)

s+.so :3'313 rz.rcsz :3'3330

sc.so :3'3i3 rz.rqsz :3'33??

sc.zs :3'313 rz.rgss :3'3331

sa.zs :3'333 rz.rgss :3'33?i

0.03 ...0.07 (0.0012 ...0.0028)

. t

tr

ENGINE M 1O

11-14a

818

1121 ... Crankshaft and Bearings - Triple Classification -

Ground sizes of main bearing journalsStandard size yellow mm (in.l

green mm (in.)

white mm (in.)

s4.984 ... 54.990 12.1647 ... 2.1650)

54.977 ... 54.983 12.1644 ... 2.1647 |

54.97 1 ... 54.976 12.1642 ... 2.16441

Undersize 1 yellow mm (in.l(0.25mm1

-0.010") green mm (in. l

white mm (in.l

54.7 34 ... 54.7 40 12.1549 ... 2.1 551 I

54.727 ... 54.733 12.1546... 2.1548)

54.721 ... 54.726 12.1544 ... 2.1 546)

Undersize 2 yellow mm (in.l(0.50 mm | -O.O2O"| green mm (in.l

white mm (in. l

54.484... 54.490 (2.1450 .,. 2.14531

54.47 1 ... 54.47 6 (2.1445 ... 2.1M7 |

Undersize 3 yellow mm (in.l(0.75 mm I -0.030") green mm (in. l

white mm (in.)

54.234 ... 54.240 12.1352 ... 2.13541

54.227 ... 54.233 (2.1 349 ... 2.13521

54.221 ... 54.226 12.1347 ... 2.13491

Radial bearing play mm (in.) 0.020 ...0.046 (0.0008 ...0.00181

ENGINE M 10

11 21 ... Crankshaft and Bearings

3o.o I3:313 (1.181.l l3:3331,eo.z | 3.331 (1.,8e0 l3:33o3,so.c | 3.333 n.,e6B l3:33i3,so.e | 3:3!3 n.zo4t l3:33?3,0.085 ... 0.174 (0.0033 ... 0.0069)

Ground sizes of crankshaftthrust bearing width

Standard size

Oversize 1

Oversize 2

Oversize 3

Crankshaft axial play

mm {in.l

mm (in.)

mm (in.l

mm (in.)

mm (in.)

ENGINE M 10

11-15a

Ground sizas of connecting rodbearing journals

Standard size

Undersize 1

Undersize 2

Radial bearing play

Ground sizes of connecting rodbearing journals

Standard size

Undersize 1(0.25 mm/0.010"1



mm (in.) 48.00 - 9'99: n.BBe8 -9'9995

mm {in.) 41.7s: 3:333 n.87ee :3:33?fi,mm (in.l 4z.so: 6:ili n.s7o1 l:#ffi rmm (in.l 0.03 ... 0.07 (0.0012 ... 0.00281

mm {in.} 47.975... 47.991 (1.8888 ... 1.88941

mm (in.) 47.725 ... 47.741 ( 1.8789 ... 1.87961

mm (in.) 47 .475 ... 47 .4s1 ( 1.8691 ... 1.8697)

mm {in.l 47.225 ...47.241 (1.8592 ... 1.8599)

1121 .. . Crankshaft and Bearings

Radial bearing play mm (in.l 0.020 ... 0.055 (0.0008 ... 0.00221

t' t . .r t q

ENGINE 10

11 - 16

818

11 21 .., Crankshaft and Bearings

Max. permissible imbalance ofcrankshaft (dyn. without f lywheell

gcm

Measuring planes

Take-up

Balancing speed rpm

50

center of bearing journal

on ends of crankshaft in vees

500

Max. permissible runout oncenter main bearing journal{crankshaft taken up on outerbearing journals) mm (in.l 0.1 (0.0041

Crankshaft throw mm (in.l 71 *0.1 12.795 r0.004)

Max. permissible surface f inishon bearing journals Rt (p) 1.5

ENGINE M 10

Max. axial runout measured onoutside diameter

Minimum thickness of flywheel{distance "A"l

818

mm (in.) 0.1 (0.0041

mm (in.l 23.6 _ s.1 (0.929 _ 0.004)

1122... Flywheel

t1 t"E

ENGINE M 10

11- 18

818

11 24... Connecting Rods and Bearings

Big end diameter mm (in.) | 52.000...52.010 12.0472...2.0476't

- Double Classification -

Big end diameter

"* mm (in.l

| 52.000 ... 52. N8 12.0/,72 ... 2.c,.761

Blue * t

Conrcd bu.hinE Ioutrid.diamerer mm(in.) | 24.060...24.100(0.9472...o,94a81

Inridodiam.ter mmti".r I zzi$.ffiro.eeeri$.$$$lrM.x. devistion in par.ltel otconrod bor6 lyith boaring .helh Iat 150 mm {5.905") di$rnco mm(in.) I 0.04 (0.Oot6)

Max. permir.ible displacsmont Ito onE rid€ | 0o 30,

Pormisriblo dsviation io wright otconnectin! rodr in ono lngine I("ith"ra b*.ing .h"ll. a 4

8ig end o lxz

small ord g

I

ENGINE M 10

11 - 19

818

1125... Pistons Pistons and pins are matchd - only replace together

Weight class (engraved orinscribed) +or-

(weight difference of separate pistons max. 10 gramsl

ldentif ication on piston skirt size and arrow for installed direction

Piston diameterStandard size mm (in.l

Special size m (,"J

Oversize 1 mm (in.)

Oversize 2 rt (i"J

88.e7 13.50271

89.05 (3.50591

89.22 (3.51261

89.47 13.52241

Piston installed clearance mm (in.l 0.02 ... 0.05 (0.0008 ...0.0020)

Max. permissible total wearclearance between piston andcylinder (engine runl mm (in.l 0.1 .. . 0.15 (0.004... 0.006)

ENGINE M 10

11 25... Piston Rings

l st groove(plain compression ringf

End clearance

mm (in. l

mm (in. l

3rd groove(double-bevelled oil control ringl

End clearancb mm (in.l

0.06 ... 0.09 (0.0024 ... 0.0035)

o.2 ...0.4 (0.008 ... 0.0161

0.03... 0.072 (0.0012 ...0.00281

0.25 ...0.5 (0.010 ...0.0201

0.02 ... 0.06 (0.0008 ... 0.00241

{ ,

ENGINE M 10

11 *21

818

11 31 ... Camshaft

Driva single roller chain

11 31 ... Chain Tensioner Piston

Piston length mm (in.) 62l2.441l

Relaxed spring lengrth mm (in.l 155.5 16.1221

11 33 ... Rocker Arms

Radialplay mm (in.) 0.016 ...0.052 (0.0006... 0.00201

f, t2I

ENGINE M 10

11 -22

818

11 34 ... Valves

Valve clearanceIntake and exhaust

At coolant tomporaturo ofmax.3so c (gso F)

At operating temperaturo(thormostat activatodl

Min. valve head edge thicknossMachining limit (distance "A"l

lntake

Exhaust

Head dia. (distance "T"lIntake

Exhaust

Stem dia. (distance "S"lStandard sizeOversize 1Oversize 2

Max. wear clearance botweenvalve stem and valve guide(tilt clearance "K")

U'Cmm (in.l

-i l"f gmm (in.l

mm (in.l

mm (in.l

mm (in.i

mm (in.l

mm (in.lmm (in.lmm {in.l

mm lin.l

0.20 (0.0081

0.25 (0.010)

1.3 (0.0511

2.0 (0.0791

46 (1.8111

38 (1.496)

8.0 (0.31518.1 (0.31e)8.2 (0.323)

0.8 (0.0311

ENGINE M 10

11 40 ... Oil Supply

forced oil circulation withpressure control valve infiltered oil circuit

Lubricating system

Oilgrade

Totaloi l volume ltr. (pts.)

Oilvolume in fi l ter ltr. (pts.)

Max. oil consumption in liters(pints) per 100 km (62 miles)(see page 9) ltr. {pts.l

"r[r:

{

ENGINE M 1O

11 41 . . . Oi l Pump

Oil pressure at idle speed

Oil pressure at max. speed

Radial play between outorrotor and pump housing mm {in.}

mm ( in. l

mm (in.l

mm (in.l

mm (in.l

Axial play between rotor andpump housing

Clearance between inner andouter rotors

Distance between f lange andinner rotor

Eaton rotor type oil pump

0.5 ... 2.017 ... 281

4.0 ... 5.0 (57 ...711

0.1 ...0.15 (0.004... 0.0061

0.04.. . 0.1 (0.0016.. . 0.00401

o.12 ... 0.20 (0.005 ... 0.0081

42.7 11.6811

\I

ENGINE M 10

11 -25

818

11 42... Oil Fi l ter

Full f low oi l f i l ter

Bypass valve opening pressure bar (psi) 2.5 (35)

11 51 ... Watsr Pump

Clearance bstween cover inhousing and impeller mm (in.l

Distance from upper "r* "flange to end of shaft mm {in.l 3.0 . . . 3.5 (0.118 . . . 0.1381

ENGINE M 10

1152... Fan Cqupting

Switching-on temperature oc {oFl

rpm

oc (oFl

rpm

rnt fi"J

Switching-off temperature

Max. speed

Fan diameter

Axial rotor play

BEHR(temperature and speed controlled viscous fan coupling)

72.. .80 (162.. . 1761

65 . . .70 {14e.. . 1581

400(15.7118)-SBlades

11 53 ... Thermostat (Coolant)

opening temperaturs(inscribed in Thermostatl oC (oFl approx.80 (1761

it t' \

ENGINE M 20

11 - 30

827

3251A325e I A325asl A528e1 A

825

325 ilA


Bore mm (in.l 84 {3.307} 84 {3.3071

Stroke mm (in.l 81 (3.18e) 75 (2.9531

Displacement, effsctive cm3 {in.3l 2693 (164) 2494 1152l.

Compression ratio 9.0: 1 8.8:1

Max. power outputto DtN 7OO2O KW (hpl e0 (1211 125 (1681

at engino speed rpm 4250 5800

Max. engine speed rpm 5000 6200

Max. torque Nm (ft lbs) 230 (1701 222 11641

at engins speed rpm 3250 4300

Compression pressure(approx. equal value for allcylindersl bar {psi) 10 . . . 11 1142.. . 1561 10.. . 11 1142.. .1561

t

-1

\!

ENGINE M20

Fuel consumptionCity


Highway

Composite (55 % cityand 45 % highwayl

Highway


1986 Models


Composite (55 % cityand 45 % highway)

325-21325 es

mpg

mpg

mpg

3254 I 325 e 325 A I 325 eA / 32S esA

22.1

I l.

t q

ENGINE M 20

11 -32

1987 Models

325 | 325 A 325e l325eA325 es / 325 esA

325' i 1325 iA

Fuel ConsumptionCity mpn

Highway mpg

Gomposite (SS % city and45 % highway) mpg

23.7 122.1 23.7 122.1 19.8 / 19.4

36.4134.6 35.3 / 34.6 29.5 | 28.1

28.1 126.4 27.8126.4 23.2122.51987 Models 325 is / 325 isA 32S i Conv. I gZS iA Conv.

Fuel ConsumptionCity

Highway lmg

Composite (55 % city and45 % highwby) mps

19.8 / 19.6 19.4 | 19.2

29.5128.1 29.9 128.4

23.2122.7 23.O 122.5

t,

11-

ENGINE M 20 528 e 528 elA

1983 Models

Fuelconsumption

Composite (55 To city and45 % highway)

City 22.O 20.4

32.6 28.4

25.7 23.4

1984 Modelr

Fu6l conlumptioncitv mps I zz.o I zr .s IHishway mpg I oz.o I re.o Icompodo (55 % city and | | f4s 96 hishway) mps | 2sJ I zs.z I

1985 Modol.

Fu6l con'mptioncity mps I zz.o I zr.s IHishw.y mps lrz.o I ss.o IComFo.ito (55 96 city and I I I4s % hishway) mpe I zs,z I zs.t I

:'\

)

ENGINE M 20

11 -34

528 e 528 eA

1986 Models

Fuel consumptionCity mpg 22.6 20.2

Highway mpg 31.3 31.3

Composite (55 % city and45 % highwayl mpg 25.8 24.O

1987 Models



Composite (55 % city and45 % highwayl mpg 25.8 24.0

\It

ENGINE M 20

11 - 39

DETERMINING OI L CONSUMPTION

Oil consumption measurements can be made after car has beendriven about 7,500 km or 4,500 miles.This distance is necessary before the oil consumption will havebecome stable.Requirement: engine must not leak oil.

Max. permissible oil consumption is 0.15 ltr./l00 km( 1 quart per 390 milesl.

Accurate oonsumption values are determined by weighing.Drain engine oil at operating temperature. Allow 5 minutesdrip time. Weigh and add specified amount of new engine oil.Drive car 1,000 km or 600 miles. Drain engine oil at operatingtemperature and weigh. Allow 5 minutes drip time. Engine oilspecific gravity at room temperature is approx. 0.9 kg/dm3.

Example: added oil - drained oil = consumed oil45009 -36009 =9009

900 :0.9 = 1000 cc = 1 ltr. per 1000 km

Possible Causes for Excessive Oil Consumption:

1. Engine not broken in fully.2. Valve stem seals damaged.3. Pistons seized.4. Piston rings installed incorrectly, broken or worn.5. Excessive clearance between valve stem and valve guide.

ENGINE M 20

CyfindersBore dia. -

Standard size

Special size

lst oversize

2nd oversize

Surface finish

mm (in.l

mm (in.l

mm (in.)

mm (in.)

Bt $)

mm (in.l

mm (in.)

827

Max. permissibfe cylinderoore outof-true

Max. permisible cylinderoore conicity

11 11 ... Crankcase

84.00 + 0.01 13.3971 + 0.00941

84.08 + 0.01 13.3192 + 0.0004f

8425+ 0.01 133169 + 0.00041

84.b0 + 0.01 13.3269 + 0.00041

I

\

ENGINE MzO

11 -42

827 825


mm (in.l

Valve guide dia. - bore dia.Standard size mmOversize 1 mmOversize 2 mm IOversize 3 mm

]Total length mm (in.l

It

Valve guide inside dia. I(installed) |

Standard size mm IOversize 1 mm IOversize 2 mm I

Instatling temperature ICylinder head oC {or} |vatve guiOe oC (oFl

I

Valve guide protrusion mm (in.) |

Cylinder head height(machining limit)


124.7 @.s0el

Old Version / New Version (lnstalled Retroactivelyf

13.0 u6 - 13.0 M7 I 13.2 u6 - 13.2M713.1 u6 - 13.1 M7 I 13.3 u6 - 13.3 M713.2 u6 - 13.2 M7 I 13.4 u6 - 13.4 M713.3 u6 - 13.3 M7 I -

4511.7721 I 43.5 (1.713)

7.O H77.1 H7 (applicable for old and new versions)7.2H7

+ 50 l+ 1221- 150 (- 238)

14.5 (0.579)

ENGINE M 20

11 -43

827 825


Valve seat insert dia. - bore dia.lntake

Standard size mmOversize 0.2 mm mmOversize 0.4 mm mm

42.15 g6 - 42.00 H742.35 gG - 42.20 H742.55 sG - 42.40 H7

43.15 g6 - 43.00 H743.35 gG - 43.20 H743.55 g6 - 43.40 H7

ExhaustStandard sizeOvercize 0.2 mmOversize 0.4 mm

Installing tsmperatursCylinder headValve seat inserts

Valve seat angle

Correction angles

Valve seat width (distance "B"lIntake and exhaust

mmmmmm

oc (or)oc (ofl

o

mm {in.}

37.65 s6 - 37.50 H737.85 g6 - 37.70 H738.05 gG - 37.90 H7

+ 50 e 1221- 150 (- 2381

45

15175

1.65 r 0.35 (0.065 r 0.014)

Valve seat dia. (distance "M"lIntake mm (in.) 38.6 (1.520) 40.6 (1.5981

Exhaust mm (in.) 32.6 (1.2831 34.6 (1.362)

ENGINE M 20

11 -M

827 825

11 21 .,. Crankshaft and Bearings - Double Glassification -

Ground sizes of main bearing jourhalsStandard size red mm (in.l

mm ( in. l

60.00 : 3:313 e.s6z2 : 3:333160.00 : 3:313 e.s6z2 : 3:331?

Undersize 1 red mm (in.l

-

be.7s :3:313 e.ss24: 3:3330se.7s : 3:3i3 es524 : 3:33??


blue mm (in.l

be.bo : 3.313 e.suzs : 3:333$se.Eo : 3.3i3 es425 : 3:33?l

Radial bearing play mm ( in.) 0.03 ...0.07 (0.0012 ...0.0028)

ENGINE M20


Ground sizes of main bearing journalsStandard size yellow mm {in.l

mm (in.lgreen

white mm (in.)

mm (in. lUndersize 1(0.25 mm /0.010"1

yellow

green mm (in. l

white

yellow

mm (in.)

mm (in.lUndersize 2(0.50 mm /0.020"1 green

white

mm (in.l

mm ( in. l

mm ( in.)Radial bearing play

5s.47 1 ... 5s.47 6 12.3414 ... 2.34161

0.020 ...0.046 (0.0008 ...0.00181

59.977 ...59.983 (2.3613 ... 2.3615)

59.971 ... 59.976 (2.3611 ... 2.3613)

5e.734 ... 59.740 (2.3517 ... 2.35201

59.727 ... 59.733 (2.351 5 ... 2.35171

59.721 ... 59.726 12.3512 ... 2.351 4)

59.484 ... 59.490 12.3419 ... 2.34211

59.477 ... 59.483 |.2.3416... 2.34181

ENGINE M20

11-45

827 825

1121 ... Crankshaft and Bearings

Ground sizes of crankshaftthrust bearing width

Standard mm (in.l zb.o I 3:313 (o.es$l 3:33f;1,Oversize 1 mm (in.l ,br l3ffll (o.eezr l3:33i1,Oversize 2 mm (in.l zs.r i [ [!f (l.ooool 3:3331,

Axial crankshaft play mm (in.l 0.08 ...0.163 (0.0031 ...0.00641

ENGINE M 20

11-45a


Standard size

Undersize 1

Undersize 2

Radial bearing play

Ground sizes of connecting rdbearing journals

Standard size

Undersize 1(0.25 mm / 0.010"1

Undersize 2(0.5O mm I O.O2O"I

Radial bearing play

mm (in.) 4s.oo:3:888 n.1717 :8:88?3 rmm {in.) M.7s:3.883 (1.7618 :8:83?3 rmm (in.) M.so: 3:3!8 n.z52o: 8:8313 rmm (in.l 0.03 ... 0.07 (0.0012 ... 0.0028)

mm (in.) 44.975... 44.991 (1.8888 ... 1.8894)

mm ( in. l 44.725 ... M.741(1.8789 ... 1.S796)

mm (in.) M.475 ... 44.491 (1.8691 ... 1.8697)

mm (in.l 0.020 ... 0.055 (0.0008 ... o.oo22l



ENGINE M 20

11-46

827 825


Max. permissible crankshaftimbalance (dynamic/withoutflywheell gcm 25

Measuring planes center of bearing journals no.land7

Take-up with rollers on main bearingsno.2 and 6

Balancing sped rpm 400

Max. permissible runouton center main bearing journal{crankshaft taken up on outerbearing journatsl mm (in.l 0.15 (0.0061

Grankshaft throw mm (in.) 81 r 0.1 (3.189 t 0.0041 75 r 0.1 (2.953 r 0.004)

Max. permissible bearingjournal surface finish Rt (Fl 1.5

ENGINE M 20

Max. axial runout measuredon outside diameter mm {in.l 0.1 (0.0041

Min. flywheel thickness mm (in.) 25.1 - 0.1 (0.988 - o.oo4)

Since 1985 Models mm (in.l

11 23... Vibration Damper

32.1 - 0.1 (1.264 - 0.0041

Max. radial runout mm (in. l 0.2 (0.008)

Max. axial runout mm (in.) 0.3 (0.012)

Diameter mm (in.) 20017.8741 23519.2521

Golor code gray

Since 1985 Models:Carc with manual transmissionin conjunction with heaviermass flywheel BMW No. 1 705764 1 708 852

ENGINE M 20

11-48

827 825

1124... Connecting Rods and Bearings

Connecting rod bushingOutside diameter

Inside diameter

bores with bearing shells atdistance of 150 mm (5.905"1

Max. permisible displacomontto ons side

Max. permissible deviation inweight of connecting rods inone engine(*,,nou, O..r,nn ffi

Big end

Smal lend

mm (in.l

mm (in.)

mm (in.)

o

Big end conrod diameterRed mm (in.l

mm (in.)

24.060 ...24.1(0.947 ... 0.9491

0.04 (0.00161

oo 30'

r4

+t

l+t

- Double Classification -I

II

I 48.000 ...48.008 (1.8898 ... 1.8901)I

I

I 48.009 ...48.016 (1.8901 ... 1.8904)I

t

ENGINE M 20

11 -49

827 825

1125... Pistons Pistons and pins are matched - only replace together.

Weight class(engraved or inscribedl weight difference of separate

pistons max. 10 grams * or -

ldentification on piston skirt size and arrow fordirection of installation

Piston diameter (checkpoint "A"lStandard size mm (in.l 83.98 (3.30631

Specialsize mm {in.} 84.06 (3.30941

Oversize 1 mm (in.l 84.23 (3.31611

Oversize 2 mm (in.l 84.48 (3.3260)

Piston installed clearance mm (in.l 0.01 ...0.04 (0.0004 ...0.0016)

Max. permissible total wearclearance between piston andcylinder (engine runl mm (in.l 0.01 ... 0.12 (0.0004 ... 0.00471

ENGINE M 20

11-50

827 825


lst groove(plain compression ringl

End clearance mm (in.l 0.30 ...0.50 (0.012 ... 0.0201

Side clearance mm (in.l 0.040 ... 0.072 (0.0016 ... 0.00281

2nd groove(taper face ringl

End clearance 'mm {in.} 0.30 ... 0.50 {0.012 ... 0.020}


3rd groove(double-bevelled oil control ring)

End clearance mm (in.l 0.25 . . .0.50 (0.010 . . .0.020)


?

ENGINE M 20

11 - 51

827 825

11 31 ... Camshaft

Drive toothed belt

Max. axial clearance mm (in.l 0.2 (0.008)


Radial play mm {in.} 0.0r6 ... 0.052 (0.0006 ...0.00201

ENGINE M 20

11 . . - 52

427 825

11 34 ... Valves

valvo ctearanceIntake and exhaust I

At coolant temporature of Imax.3so c (gso Fl mm (in.)

| o.zs (0.010)

At operatinn r"(thermostat activated) mm (in-l I o-go fo orzr

Min. valve head edge thickness IMachining limit (distance "A"| |

Intare mm (in. l |

1.3 (o.o51l

Exhaust mm (in.l I z.o to.ozsl

Head dia. (distance "T")Intake mm (in. l

Exhaust rr r,,",

40 (1.575) 42 fi.654!.

34 (1.33e) 36 ( 1.417)

Stem dia. (distance "S")Standard sizeOversize 1Oversize 2

Max. wear clearance betweenvalve stem and valve guide(tilt clearance "K"l

mm (in.lmm { in.)mm (in.)

7.O l0.275l7.1 l0.z7sl7.2l0.283l

mm (in.) | o.B (0.o3tl

. - ' i .

\

ENGINE M 20

11-53

827 825

11 40 ... Oil Supply

Lubricating systom forced oil circulation with prossure control valve in filtered oilcircuit

Oilgrade see Sorvice lnformation of Group 00

Total oilvolume ltr. (pts.l 4.25 (9.01

Oil volume in oil filter ltr. (pa.l 0.2s (0.51

Oilconsumption in liters (pints)per 100 km (62 milesl(see page 39) ltr. (pts.) max.0.15 (0.31

Additional oilvolume in oilcooler (only added afterrepairingl ltr. (pts.l 0.75 (1.6)

ENGINE M 20

11 41 . . . Oi l Pump

0.5 ... 2.O 17 ...281

4.0 . . .6.0 (57 . . .85)

Oil pressure at idle speed bar (psi)

Oil pressure at max. speed bar (psil

Spring length mm ( in. l M {.1.7321

' l

ENGINE M 20

11 - 55

B27 825

11 42.. . Oi l Fi l ter

Full f low oi l f i l terBypass valve opening pressure bar (psil 2.5 (35)

11 51 ... Water Pump

Clearance between cover inhousing and impeller mm (in. l 0.4 ... 0.8 (0.016 ... 0.0311

Distance from flange upperedge to end of shaft mm (in.) 4.1 . . .4.4 (0.161 . . .0.1731

-d

ENGINE M 20

11 - 56

827 825

1152... Fan Clutch

Typ! | tomplratuE md $ed con-I tlolhd virco tan clurch

Swirching.on tomD€rlrur€ oc loF) lazrl(tsorzl

IFm di.nrtcr mm (in.l | 4m 115.5i15)

Number of tan btrd6 lg

Fan lpr€d !t ongina $€od of I3500 rpm (clutch rwitchrd on) rpm | 2400 i 100

Max. rotol axlalolav mm(in.l 10.410.016)I

M!x. roror r.dial plry mm (in.) I 0,5 (0,0i101

11 53 ... Thqmo3t't (Cool.ntlI

Opening trmp€ralurc |{rtampod in thormotbt} oC loF) | rpprox. Slt (176}

\I

ENGINE M21 D24

524tdlA

11 -70

Bore dia. mm ( in. l 80 (3.1501

mm (in.l 81 (3.18e)

Effective displacement cm3 (in.3l 244.31149t,

Compression ratio

Power output to DIN 7OO2O KW {HPI 85 (1141

at engane speed

Max. engine speed 5350 r 100

Max. constant engino spaed

Max. torque Nm (ft. lbs.) 210 (1551

at engin8 speed 2400

Compression (as equal aspossible for all cylinders) bar {psi) > 2012841

11 00 ... Engina in General

ENGINE M21


FuelconsumptionCaty

Composita (55 % cityand 45 % highwayl


\

3T

f.ENGINE M 21 524 td/A


Oil consumption measursmsnts can be mad after car has beendriven about 7,500 km or 4,500 miles.This distance is necessary before tha oil consumption will havebecome stable.Requirement: engine must not leak oil.

Max. permissible oilconsumption is 0.15|tr./100 km( 1 quart per 390 miles).

Accurate consumption values are deternind by weighing.Drain engine oil at operating temperatuo. Allow 5 minutesdrip time. Weigh and add specified amotnt of new engine oil.Drive car 1,000 km or 600 miles. Drainengine oil at operatingtempsrature and weigh. Allow 5 minufs drip time. Enginqoilspecific gravity at room temporature isapprox. 0.9 kg/drn3.

Example: addd oil - drained oil = consumed oil4500g -3600s *9009900 : 0.9 = 1000 cc " 1 ltr.per 1,000 km

Possibla Causes for Excsssive Oil Con$mption:

1. Engine not broken in fully.2. Valve stem seals damaged.3. Pistons seized.4, Piston rings installed incorrectly, brcen or worn.5. Excessive clearance betwecn valvE stm and valve guide.

i

ENGINE M 21

11 - 80

D24

11 11 ... Crankcase

Cylinder bore diametarStandard size

Special size

Oversize 1

Surface finish (honed levelnessl

Max. cyl. bore out-of-true

Max. cyl. bore conicity

mm (in.l

mm lin.)

mm {in.)

Rz (p)

mm (in.l

-mm ( in.)

BO.gO + 0.01 (3.1496 + 0.0004)

80.08 + 0.01 B.$27 + 0.0004)

80rw6.. . 10

0.014 (0.00061

0.014 (0.00061

ENGINE M 21

Cylinder head height(cylinder head may not beregroundl

Max. distortion over entirelength of cylinder head

Valve guide inside diameter(installedl

Standard sizeOversize 1Oyersize 2

Valve guide protrusion

mm (in.l 148 r 0.1 (5.827 r 0.0041

mm (in.l 0.05 (0.0020)

7.O H77.1 H77.2H7

mm (in.l 13.5 (0.531)

mmmmmm



ENGINE M 21

11-83

Valve seat angle

Correction angles

Valve reat width (distance "B"lIntake

Exhaust

Valve seat dia. (distancc "M"l. lntake

Exhaust

Valve retrusion (distance "R")lntake

Exhaust

1112... Burnerc

0/65

mm (in.l 1.75 t 0.25 (0.069 r 0,0101

mm (in.l 2.75 *,0.25 (0.108 t 0.0101

mm (in.l 33.6 (1.323)

mm (in.) 29.6 (1.1651

mm (in.l 0.65 ...0.85 (0.026 ...0.033)

mm (in.l 0.85 ... 1.05 (0.033 ...0.0411

o

11 12... Valve Seats

Burnsr retrusion (distance "B") mm {in.) 0.02 ...0.07 (0.0008 ...0.00281

e3

t : .

ENGINE M 21

11-84

D24

1121... Crankshaft and Bearings - Triple Classification -

Ground sizes of main bearing journalsStandard size yellow

gresn

white

Undersize 1 yellow(0.25 mm0.010"1 green

white

Undersize 2 yellow(0.50 mm0.020") gresn

white

Radial crankshaft bearing play

mm (in.l

mm (in.)

mm (in.l

mm (in.l

mm {in.}

mm (in.l

mm (in.l

-mm (in. l

mm (in.)

mm (in.)

59.984 ... 59.990 (2.3616 ... 2.3618)

59.977 ... 59.983 (2.3613 ... 2.36151

59.971 ... 59.976 (2.361 1 ... 2.3613)

59.734 ... 59.740 (2.3517 ... 2.35201

59.7 27 ... 59.7 33 12.3515 ... 2.35171

59.7 21 ... 59.7 26 12.3512 ... 2.351 4l

59.484 ... 59.490 (2.3419 ... 2.3421)

59.477 ... 59.483 (2.3416 ... 2.3418)

59.47 1 ... 59.476 (2.3414 ... 2.34161

0.020 ... 0.046 (0.0008 ... 0.0018)

I

ENGINE M 21

Ground sizes of thrust bearingwidth on crankshaft

Standard size mm (in. l 2s.o I8:8!8 (0.e843 I8:8831rOversize 1 mm (in.l 2s.218:3!8 (o.ee2r i 3:8831Oversize 2 mm ( in. l 2s.4f,8:3!3 n.oooo I 3:3861r

Axial crankrhaft bearing play mm (in.l 0.08 ... 0.163 {0.0031 ... 0.00641

Ground sizes of conrod bearing journalsStandard size mm (in.l 44.975... 44.991 11.7707 ... 1.77131

Undersize 1 |.0.25 mm/0.010"1mm (in.l 4.725 ...M.741(1,7608 ... 1.7615)

Undersize 2 {0.50 mm/0.020"}mm (in.l M.475 ... 44.491 ( 1.7510 ... 1.7516)

Radialconrod bearing play mm {in.l o.o21... 0.055 (0.0008 ...0.00221

11 21 ... Grankshaft and Bearings

ENGINE M 21

11 21 ... Grankshaft and Bearings

Max. permissible imbalance ofcrankshaft (dyn. withoutflywheall

Measuring planes

Take-up

Balancing speed

Max. permissible runout oncenter main bearing journal{crankshaft running onouter bearing journalsl

Crankshaft throw

Max. parmissible surface finishon bearing journals

center of bearing journals I and 7

in rollerc on main bearings 2 and 6

rpm 400

mm (in.l 0.15 (0.006)

mm ( in.) 81 r0.1 (3.189 r0.004)

Rz lpl 1.5 (micro share in 1 mm/O.03g,,cut depth tpal = 70 %l

ENGINE M 21

Max. axial runout measuredon outside diameter

Min. flywheel thickness(distance "A")

Max. radial runout

Max. axial runout

mm (in.l 0.1 (0.0041

mm ( in. l 32.1 - g.1 (1.264 - 0.004)

mm (in.l 0.2 (0.008)

mm (in.) 0.3 (0.0121

mm (in.l 235le.252l

1122... Flywheel


I

ENGINE M 21

11-88

D24


Conndcti,rg rcd buthing Iourlido di.mrbr mm (in.)

| 28,060 ... 28.100 (1.1047 ... 1.10631

,n.,Oa Ot"in*, rr t,

Max, davirtion ln p!.sllsl of Iconrcd bo]! with borilrg thlllr Irt distflp ot 150 mm (5.9(E"1 mm lin.l 10.0410.00161

Max, prrmi$ibl! dirphcoment Ito ona lido o loo3cf

Max. dorriation in wlight ot Iclnnoctini rods in ono lngim I(tt,noM

Big ond e l t2

Smal l rnd s l i2

- Doubls Cla$lfic.tion -

Big ond conrcd boro di.. IRed mm (in.)

| 48.00...48.008 {1,8898 ... 1.89011

Blu! mm (in.l | 48.d!9 ...48.016 11,8901 .,, 1.8904)

(q

ENGINE

Pistons and pins are matched - only replace together

Weight class(inscribed or die stampedl * or - (max. deviation in

weight of pistons: 10 gr.l

ldentification on piston piston dia., arrow for installed direction, compression ratio

Piston diameter(measured at point "A"l

Standard size mm (in.) Alcan 79.965 (3.1482)KS 79.950 (3.14761Kiinis/Mahle 79.945 13.14741

Specialsize mm (in.l Alcan 80.045 (3.15141KS 80.030 (3.1508)Kiinis/Mahle 80.025 (3.1506)

Oversize 1 mm ( in. l Alcan 80.215 (3.15811KS 80.200 (3.15751Kiinis/Mahle 80.195 (3.15731

Piston installed clearance mm ( in.) Alcan 0.026 ...0.054 (0.0010 ...0.0021)KS 0.034 ...0.076 (0.0013 ...0.0030)K6nis/Mahle 0.046 ... 0.074 (0.0018 ... 0.0029)

Total permissible wear clearancobetween piston and cylinder(used enginel mm (in.l 0.15 (0.0061

ti

ENGINE M 21

11-90

D24


Groove 1 (keystone ring) |End clearance mm {in.l | 0.2 ... 0.4 (0.008 ... 0.016)

ISide clearance mm (in.l

| 0.06 ...0.14 (0.0024...0.00551

Groove 2 (taper face ring| IEnd clearance mm (in.)

| 0.2...0.4 (0.008 ...0.016)

Side clearance , mm (in.l | 0.05 ...0.08 (0.0020... 0.0031)

Groove 3 (bevelled ring with Irubber lined springl I

End clearance mm (in.l | 0.25...0.50 (0.010...0.0201

Side clearance mm (in.l | 0.03 ...0.06 (0.0012 ... 0.00241

ENGINE M21

Toothed belt

Axial running clearance mm (in.) 0.15 . . .0.33 (0.006 . . .0.0131

Cam distance "N"

Intake cams mm (in.l 34.023 (1.3391

Exhaust cams mm (in.l u.241(1.3481

Max. wear distance onused cam peaks mm (in.l 0.1 (0.0041

cto

o@

11 31 ... Camshaft

t-.l-\:o j\ -L i

t t \

ENGINE M21

11 -92

D24

11 34 ... Valves

Valve clearance "V"lntake and exhaust

At coolant temporaturo ofmax.3so c (gso Fl

At operating tomperoturo(thermostat activated I

Head dia. (distanco'T")Intake

Exhaust

Valve retrusion (distance "R"lIntake

Exhaust

Stem dia. (distance "S")Standard sizsOversize 1Oversize 2

Max. wear cloarance betweenvalve stem and valve guide(tilt clearance "K"l

mm {in.}

mm (in.l

mm (in.)

mm (in.)

mm (in.)

mm (in.)

mm {in.}mm (in.lmm lin.l

mm (in.)

0.30 (0.0121

0.35 (0.0141

35 (1.3781

31 11.220l

0.65 ...0.85 (0.026 ...0.0331

W

7.0 (0.275)7.1 l0.279l7.2l0.283l

0.8 (0.031)

\ . /\I

\

ENGINE M 21

Lubricating system Forced oil circulation withpressure control valve infiltered oil circuit

Seo Service Information of Gr. 00

Total oi lvolume Itr. (pa.l 5.70 (12.01

With oil cooler {only has tobe filled after repairing) 1x'. (pts.l 6.50 (13.71

Oilvolume in oi l f i l ter Itr. (pts.l

Oil consumption (see page 791 ltr./100 km max.0.15 (0.321

11 40.. . Oi lSupply

\(

ENGINE M 21

11-94

D24

1141 . . . Oi l Pump

Tvpe I cear type

Oil pressure Iat idle speed bar (psil

I o.t ... 2.o 17 ...ZBl

uarn"r. ro*

Relaxed spring tength mm (in.) | Zt.O (2.819)

t q(

ENGINE M 21

Clearance between cover inbody and impeller

Distance from upper edge offlange to end of shaft

mm ( in. l 0.4 . . .0.8 (0.016.. . 0.0311

mm (in.) 11.2 t0.1 (0.441 t 0.0041

11 51 ... Water Pump

\ \

ENGINE M 21

11-96

D24

1152... Fan Coupling

Axial play of rotor mm (in.l I max.0.4 (0.016)

Radial play of rotor mm (in.) | 0.5 (0.020)

Design I Temperature and speed con-I trolfed viscous fan couplinn .to

Switching-on tsmperature oc (of l I a"n, 82t4(1so t7lI Eaton 76 t4 (169 r7lI

I

Fan diameter mm {in.) | qzo {16.5351- l

No. of fan blades | 9

Fan speed at ongine speed of3500 rpm (coupling activatedl rpm | 2400 t 100

(

ENGINE M 21

Opening temperature(stamped in thermostatl oc {or} approx.80 (175)

11 61 ... Charging Air Pressure Blowoff Valve

\


Opening prsssuro bar {psil 1.0 r0.1 (14 r 1)

Charging air pressure (in loadrange above 2500 rpm)

Max. bearing playAxial

Radial

bar (psil o.77 ...0.83 (11 ... 12l-

mm (in.l 0.03.. . 0.08 (0.0012 . . .0.0031)

mm (in.) 0.08 ... 0.15 (0.0031 ...0.0059)

11 65 ... Turbocharger

11 66 ... Vacuum Pump

Vacuum (min.l mbar 530

\{.q

ENGINE M 30

11 -- 301

832

533 i/A633 CS|/A733,1A

834

53s i/A635 CS|/A735i lA

835

735.1A (E 321

11 00... Engine in General

Bors mm (in.l 8e (3.5041 e213.622l- e213.6221

Stroke mm (in.) 86 (3.386) 86 (3.386) 86 (3.386)

Effective displacement cm3 (in.3l 3210 (1e6) 3430 (20s1 3430 (20e)

Compression ratio 8.8:1 8.0: 1 9.0: 1

Power to DIN 7OO2O KW (HP) 135 (1811 136 (182) 155 (2081

at engane speed rpm 6000 5400 5700

Max. engine speed tpm 6300 6100 6200

Max. constant engino speed rpm 6000 6000 6000

Max. torque Nm (ft lbsl 265 11921 zso 12141 30E12251

at engino speed rpm 4000 4000 4000

Compression prossuro(approx..equal value for allcylindenl bar (psi) 10.. . 111142.. . 156) 10.. . 111142.. . 1561 10.. . 11 (142.. . 1561

f

\ \c

ENGINE M 30

11 -302

533 i633 CSi733 i

533 i/A633 CSa/A733alA

1983 Models

Fuelconsumption

city mpg 19.0 18.4

Highway mpg 29.O 24.9

Composite(55% city and45 % highway) mpg 22.5 20.8

[ '

533 iENGINE

11 - 303

FuelconsumptionCity mpg

Highway mpg


1985 Models

FuelconsumptionCity

Highway


1986 Models 535 i 535 iA 535 iA (EH Transmission)

EH = Electronic/Hydraulic

Fuel consumptionCity mpg 17.3 19.2 18.3

Highway mpg 28.1 30.3 27.1

Composite (55 % cityand 45 % highway) mpg 21.O 23.O 21.5

ENGINE M 30

11 - 304

535 i 535 iA (EH Transmissionl

1987 Models

Fuel consumptionCity mpg

Highway mpg

Composite (55 % city and45 % highway) mpg

17.3 18.3

28.1 27.1

21.O 21.5

ENGINE M 30

FuelconsumptionCaty

Highway


1985 Models

FuelconsumptionCity

Highway

Composite {55 % cityand 45 % highway)

1986 Models 635 CSi 635 CS|A 635 CS|A (EH Transmission)


Highway mpg 28.8 27.6 25.5

Composite (55 % cityand 45 % highwayl mpg 21.6 20.8 19.9


i (

ENGINE M 30

11 - 306

L6 LGA(EHTransmissionl M6

1987 Models

FuelconsumptionCity mpg 17.9 16.8 11.2

Highway mpg 28.8 25.5 24.2

Composite (55 % city and45 % highway) mpg 21.6 19.9 14.8

ENGINE M 30

FuelconsumptionCity

Highway


1985 Models

FuelconsumptionCity

Highway


1986 Models


735 i 735 iA 735 iA (EH Transmissionl


Highway mpg 26.2 26.3 24.3

Composite (55 % cityand 45 % highway) mpg 19.9 20.4 19.5

(

ENGINE M 30

11 - 308

E32735 i

E32735 iA (EH Transmission)

1987 Models

FuelconsumptionCity mpg 16.7 16.0


Composite (55 % city and45 % highwayl mpg 20.7 19.1

ENGINE M 30

11 - 3ff)


Oil consumption measursments can be made after car has beendriven about 7,500 km or 4,500 miles.This distance is necessary before the oil consumption will havebecome stable.Requirement: engine must not leak oil.

Max. permissible oil consumption is 0.15 ltr./l00 km( 1 quart per 390 milesl.

Accurate consumption values are determined by weighing.Drain engine oil at operating temperature. Allow 5 minutesdrip time. Weigh and add specified amount of new engine oil.Drive car 1,000 km or 600 miles. Drain engine oil at operatingtemperature. Allow 5 minutes drip time. Weigh drained oil.Engine oil specific gravity at room temperature is approx.0.9 kg/dm3.

Example: added oil - drained oil = consumed oil4500g -36009 =900g

900 : 0.9 = 1000 cc = 1 ltr. per 1000 km


1. Engine not brokin in fully.2. Valve stem seals damaged.3. Pistons seized.4. Piston rlngs installed incorrectly, broken or worn.5. Excessive clearance between valve stem and valve guide.

ENGINE M 30

11 11 ... Crankcase

89.00 + o'ol 6.solg + o.oott4) 92.00 + 0.01 6.OZeo +0.0004)

Bg.0B + 0.01 13.5971 + 0.001141 gZ.0B + 0.01 (g.OZSZ + 0.00t141

892b + 0.01 (g.gtgg + 0.00041 gZ.Z5+ 0.01 6.Ortg + 0.001141

89.50 + 0.01 (g.rzro + 0.00041 92.50 + 0.01 (3.6417 + 0.001!4)

Cylinder bore dia.Standard size

Special size

Oversiza 1

Oversize 2

Surface finish

Max. permissible cytinder boreout-of-trua

Max. permissible cylinder boreconicity

mm (in.)

mm (in.l

mm (in.l

mm (in.)

Rt (p)

mm (in.)

mm (in.l

92.00 + 0.Ol rc.6221+ O.

92.0g + 0.01 (3.6252 +

92.25 + 0.01 (3.ffi19 +

92.50 + 0.01 (3.6417 + o.

3 . . .4

0.01 (0.0004)

0.01 (0.00041

ENGINE

r 311


Cylinder head height(machining limitl mm (in.l 128.6 (s.0631


Valve guide dia. - bore dia.Standard sizeOversize 1Oversize 2Oversize 3

mmmmmmmm

14.2 u6 - 14.2M714.3 uG - 14.3 M714.4 uG - 14.4M7

Total length mm (in.l 50.5 {1.988}

Valve guide inside diameter(installedl

Sandard sizeOversize 1Oversize 2

8.0 H78.1 H78.2 H7

I nstalling tsmperatureCylinder headValve guide

oc (orloc (orl

+50 l+1221- 150 (- 2381

Valve guide protrusion mm (in.) 13.5 (0.5311

14.0 uG - 14.O M714.1 uG - 14.1M714.2uG - 14.2M714.3 uG - 14.3 M7

g t \

ENGINE M 30

11 - 312

832 834 835

11 12... Valve Seat Inserts Old Version / New Version (lnstall Retroactivalyl

Valve soat imert dia. - bore dia.(distance "D")Inuke

Sundard sizeOversize 0.2 mmOversize 0.4 mm

ExhaustStandard sizeOversize 0.2 mmOversize 0.4 mm

mmmmmm

mmmmmm

Valve seat insert height - bore depth(distance "H"l

Sundard sizeOversize 0.2 mmOversize 0.4 mm

I nstal I ing temperaturoValva seat insertCylinder head

mmmmmm

oc (oFloc (on

New version

Valve seat anglo o

Correction angles o

Valve seat width (distance "8")lntakeExhaust

mm (in.lmm (in.l

47.15 s6 -47.00 H747.38 gG - 47.2O H747.55 gG - 47.4O H7

III

48.15 sG - 48.00 H748.35 gG - 48.20 H748.55 sO - 48.40 H7

40.15 gG - 40.00 H740.35 s6 - 4O.2O H740.55 g6 - 40.40 H7

: rn1-7.35Hl l

III

7.5 + 0.1 - 7.35 Hl17.7 + O.1 - 7.55 Hl17.9 + 0.1 -7.75 HlI

- 150 (- 2381

4515175

1.4 r 0.4 (0.055 r 0.01611.7 t 0.4 (0.067 r 0.0161

ENGINE M 30

Valve seat diameter{distance "M"}

Intake mm (in.)

mm (in.l 36.6 (1.4411


rt4.6 (1.756)

\Ie.\

ENGINE M 30

11 - 314

832 B34

11 21 .,. Crankshaft and Bearings - Double Classification -

Ground sizes of main bearing journalsStandard size red mm (in.)

blue mm (in. l

60.00 :3:313 es6zz:3:3333 ,

60.00:3:333 Qslzz:3.33?? ,Undersize 1 red mm (in.l

blue mm (in. l

se.7s :3:313 elsz4:3:3333 ,

se.zs :3:313 e.ss24:3:33?l ,


blue mm (in. l

be.so :3:313 es42l:3:3333 r

59.50:3:313 Qs42s - 3:33?l ,

Undersize 3 red mm (in.)

blue mm (in.)

se.2s:3.313 e.sszl- 0.0004- 0.0008)

59.25- 3:313 ess2t :3:331?)

Radial crankshaft bearing play mm (in.l 0.03 ...0.07 (0.0012 ...0.0028)

. t -

t:\

ENGINE M 30

11 - 31s

832 834 835


Ground sizes of main bearing journalsStandard size yellow mm (in.l

ffi

white mm (in. l

5e.e84 ... 5e.990 (2.3616 ... 2.3618)

59.s77 ... 5e.e83 (2.3613 ... 2.36151

59.971 ... 59.976 (2.3611 ... 2.3613)

Undersize 1 yellow mm (in.l(0.25 mm0.010"1 green mm (in.l

white mm (in.)

59.734... 59.740 12.3517 ... 2.35201

59.727 ... 59.733 (2.351 5 ... 2.35171

59.721 ... 5s.726 12.3512 ... 2.351 4l

Undersize 2 yellow mm (in.)(0.50 mm I .0.020"1 green mm {in.l

white mm (in. l

59.477 ... 59.483 (2.3416 ... 2.34181

59.47 1 ... 59.476 12.3414 ... 2.34161

Undersize 3 yellow mm (in.l(0.75 mm0.030"1 green mm (in.l

white mm (in.)

59.234 ... 59.240 12.3320 ... 2.33231

59.227 ... 59.233 (2.3318 ... 2.33201

59.221 ... 59.226 (2.331 5 ... 2.3317 |

Radial crankshaft bearing play mm (in.l 0.020 ... 0.046 (0.0008 ... 0.00181

(q \

ENGINE M 30

11 - 316

832 834 835


Ground sizes of crankshaft thrustbearing width

Standard size

Oversize 1

Oversize 2

-Oversize 3

Axial crankshaft bearing play

mm (in.l

mm {in.}

mm (in.l

mm (in.l

mm (in.l

so.o I 3 331 rr.rsr r I 3'33i3rso.z I 3'3ll tr.r 8ro I 3 33?3 rgo.c I 3 3!l rr.rg68 l 3'33?3rgo s l3'3!l rr.zoaz 13 33?3r0.085 ... o.17 4 (0.0033 ... 0.00691

R

ENGINE M 30

11 - 317

832 834 835



Standard size mm {in.} 48.00: 8:888 (1.BBeB : 3:3393rUndersize 1 mm (in.l 47 .zs - 8:888 (1.8zee : 8:8893rUndersize 2 mm (in.) 41.5o: 8:898 (1.8zor : 3:33?3rUndersize 3 mm (in.) 4z.zs: 8:898 (1.8602 : 3:33?3'

Radial conrod bearing play mm (in.l 0.03 ... 0.07 (0.0012 ... 0.00281

- Doobls Clrtriticrtion -

Ground siz.r ot connocting rod Iboaringlournalr I

Standard 3izo mm (in.l | 47,975 ,.. 47.901 11,8888 ... i.8894)

undonizs 1 (0.25 mm) mm {in.l I 47.725...47.741 (1.8789 ,.. 1.8796}

Und...iro 2 (0.50 mml mm (in.l | 47,'Y5 ... 47./Ol (1.8691 ... 1.8697)

UndoFiro 3 10.?5 mml mm (in.) | 47,225 ... 47.2'll (1.8592 ... 1.8599)

Radial coniod beiring dry mm lin,l | 0.OI0 .,.0,065 (0.0m8... 0.lxl22)

\(

ENGINE M 30

11 - 318

832 834 835

1121 ... Crankshaft and Bearings

Max. permissible crankshaft Iimbalance (dynamic/without It t -hm' l*r l

,*IMeasuring planes

, I on main bearings 1 and 7 - middle of brg. iournal

ITake-up l_

on main bearings 1 and 7

Balancing spoed rpm |

500I

Max. permissible runout on Icsnter main bearing iournals I(crankshaft taken up on outor Ibearing iournalsl mm (in.l

| 0;1 (0.0041

Crankshaft throw mm (in.l | 86 t 0.1 (3.386 t0.004)

Max. permisible bearing Iiournaf surface finish Rt (pl | 2

ENGINE M 30

Max. axial runout measuredon outsids diameter

Min. flywheel thickness

mm (in.l

mm { in.}

0.1 (0.004)

26.6 _ s.1 (1.0 7 _ 0.0041

11 22.. . Flywheel


Max. radial runout mm (in.l

Max. axial runout mm (in.l

0.2 (0.0081

0.4 (0.016)

Diameter mm (in.l 245 {9.646) 253 (e.961)

Color code black graY green

Since 1985 modelsFor manuals in conjunction withheavier mass flywheel BMW no. 1 706 595 1 705 215

t{(t.\

ENGINE M 30

11 - 320

832 834 835


Big end diameter mm (in.l 52.000 ... 52.010 12.0/-72 ...2.04761

IRed mm {in.l iBlue mm (in.l I

Connecting rod bushing IOutside diameter mm (in.l

lI

Inside diameter mm (in.l II

Max. deviation in parallel of Iconrod bores with bearing shells iat distance of 150 mm (5.905") mm (in.l

I

Max. permissible displacemont Ito one side o

Max. dwiation in weight ofconnectang rods in one engine(*,,hou, O..rinn rhtt

Big end g

Small end g


52.OOO ..: 52.0O8 12.0472 ... 2.047 6l

52.009 ... 52.016 .2.0476 ... 2.04791

24.060 ... 24.100 il0.9472... 0.9488)

,r l8:338 (0.8661 i 3:8831r

0.04 (0.0016)

Ioo 30'

III

I *oI

I

l !2I

II

I t2I

E \

ENGINE M 30

11 -321

832 834 835

11 25... Pistons

Weight class(inscribed or stamped)

+or_(maximum deviation in weight of pistons = 10 grams)

ldentification on piston piston diameter, arrow for installed direction, compression ratio

Piston diameter(measured at point "A")

Standard size mm (in.l 88.97 (3.50271 91.97 (3.620e1 Afcan: 91.972 (3.62091Mahle: 91.980 |.3.62121

Specialsize mm (in.l 8e.05 (3.5059) 92.05 (3.6240) Alcan: 92.052 (3.6241)Mahle: 92.060 (3.62/t4)

Oversize 1 mm (in.l 89.22 (3.s126) 92.22 (3.6307) Afcan: 92.222 (3.6308)Mahfe: 92.230 (3.63111

Oversize 2 mm (in.) 89.47 13.52241 s2.47 (3.64051 Af can: 92.472 (3.6406)Mahfe: 92.480 (3.64091

Piston running clearance mm (in.l 0.02 ...0.05 (0.0008 ...0.00201

Total permissible wear clearancebetween piston and cylinder(used enginel mm (in.l 0.02 ...0.15 (0.0008 ...0.00591

ENGINE M 30

11 -322

832 834 835


lst groove(plain compression ring|

End clearance mm (in.l 0.30 . . .0.50 (0.012 . . .0.020)

Side clearance mm (in.) 0.05 ...0.082 (0.0020 ...0.0032) 004.. 0.072 (0.0016 ...0.0028)


End clearance mm (in.) 0.20 ... 0.40 (0.008 ... 0.016) 0.4 ...0.65 (0.016 ...0.0261

Side clearance mm (in.) 0.04 ... 0.072 (0.0016 ...0.0028) 0.03 ... 0.062 (0.0012 ...0.00241

3rd groove(double-bevelled oil control ringl

End clearance mm (in.l 0.25 . . .0.50 (0.010 . . .0.020) 0.3 ... 0.6 (0.016 ... 0.0241

Side clearancs mm {in.} 0.02 ...0.052 (0.0008 ...0.00201 0.02 ...0.055 (0.0008 ... 0.00221

832ENGINE M 30

Axial running clearance mm (in.)

Piston length mm (in. l

Relaxed spring length mm (in.l

single roller chain

0.03 ... 0.18 (0.0012 ... 0.00711

61.8 ... 62.0 12.433 ...2.4411

155.5 16.1221

11 31 ... Chain Tensioner Piston


Radial play mm (in.l 0.016 ... 0.052 {0.0006 ... 0.00201

ENGINE M 30

11 - 324

Valve clearancelntake and exhaust valyes

At coolant temperature ofmax.35o C {gso F}

At operating tsmporature(thermostat activated I

Min. valve head edge thicknessMachining limit (distanco "A"l

IntakeExhaust

Head diameter (distanca "T"llntakeExhaust

Stem diameter (distanco "S")Standard sizeOversize 1Oversize 2

Max. wear clearance betweenvalve stem and valve guide(tilt clearance "K"l

mm (in.)mm (in.l

mm (in.lmm {in.l

mm (in.)

mm (in.l

mm (in.lmm (in.lmm ( in. l

0.30 (0.0121

0.35 (0.014)

1.3 (0.0s112.0 (0.0791

8.0 (0.315)8.1 (0.31918.2 (0.323)

47 (1.811138 (1.4e6)

46 (1.811)38 (1.4961

mm (in.l 0.8 (0.0311

ENGINE M 30

11 - 325

832 834 835

11 40.. . Oi lSupply

Lubricating system

Oilgrade

*,.t ",t

r"trr" t,

Without filter replacement ltr. (pts.l

Including oil cooler(only fillafter repairingl ltr. {pts.l

Forced oil circulation with prsssure control valve in filtered oilcircuit

Refer to Service lnformation of Group 00 for approved oils

Oilvolume in oi l f i l ter Itr. (pts.)

5.75|.12.11

'5.00 {10.6)

6.50 (13.7)

0.75 (1.6)

max.0.15 (0.321Oil conilmption (see page 691 ltr./100 km

ENGINE M 30

11 - 326

Design

Oil pressure at idle speed bar (psil

Oil pressure at max. speed bar (psil

Radial play between outerrotor and pump housing mm (in.l

Axial play between rotor andpump housing mm (in.l

Clearance between inner andouter rotors mm (in. l

Relaxed spring lengith mm (in.)

Distance between flange andinner rotor mm (in.)

834

Eaton rotor type oil pump

0.5. . . 2.017.. .281

4.0. . .6.0 (sz . . .711

0.1 ... 0.15 (0.004... 0.006)

0.04... 0.1 (0.0016 ... 0.0039)

o.12 ...0.20 (0.005 ... 0.0081

68 (2.6771

44.3 r O.1 11.744 r 0.004)

11 41 . . . Oi lPump

ENGINE M 30

11 - 327

832 834 835

11 42 ... Oil Fi l ter

Full llow oilfiltsr IIt -Bypass v8fvo oponfng prc$urs bar (Fil | 2.3 ,.. 2.7 {3:} .,. 381

tt t- tt"* t *

Cleatanco botw€on ooYgr inho,rrind,nd imp€[.r mm lin.l | 0.4...0.8 (0.028 ...0.0431 | 0.4... 1.2 (0.028 ... Oo'|7l

DiJtancs trom r€.ling lt|rftcr Iof wstsr pump to uPp€r dgs Iol flansc mm (in.) | 99.8 (3.9291

Dinlnc8 trom uppor edg6 offtang€ to 6nd ot shdt mm {in.) | 2.6 ... 2.9 (0.102 ... 0.1141 |

ra

t ' II

ENGINE M 30

11 -- 328

832 834 835

11 52 ... Fan Cturch

Type I rpeoa dcprndenr vircour fin AuGh IFan diameter mm (in. l 420 (16.535) 420 (16.535) 450117.7161Number of fan blades I I 7Speed at engine speed of3500 rpm rpm 3300 r 400 2500 t 200 2000 I 200

Type

Switching-on temperature oC (oFl

Switching-off temperature oC (oFl

temperature and speed dependent viscous fan ctutch

82r4(180r71

\ 60 (1401

Fan diameter mm (in.lNumber of fan blades

400 (15.748)8

420 (16.535)I

420 (16.535111

Speed at engine speed of3500 rpm (clutch onl rpm 2400 * 100 2400 t 100 2100t 100Axial play of rotor

Radial play of rotor

mm (in. l

mm (in. l

max.0.4 (0.016)

0.5 (0.0201

ENGINE M 30


Opening temperature(inscribed in thermostatl approx. 80 (1761

. \

ENGINE

1r -800

s14M3

s38M5M6


Bore mm {in.} 93.4 (3.6771

Stroke mm (in.l 84 (3.307)

Effective displacement cm3 (in.3l 23021140.41 3453 (210.6)

Compression ratio 10.5 : 1 9.8: 1

Powar to DIN 70 O2O KW at rpm 143 at 6750 191 at 6500

Permissible top speed rpm 7250 6800

Permissible constant speed rpm 6900 6600

Max. torque Nm (ft. lbs.l/rpm 230 (166) I 4750 330 (239) I 4500

Compression prsssure(approx. same value for allcylindersl bar (psil at least 10 to 11 (143 to 1561

d

ENGINE S 14s38

11 *801

M3 M5 M6

1987 Models



Composite (55 % city and45 % highwayl mps 14.9 14.8

(;(

ENctNE S14/S38

11 -802

DETERMINING OIL CONSUMPTION

Oil consumption measutements can be made after car has beendriven about 7,500 km or 4,500 miles.This distance is necessary before the oil consumption will havebecome stable.Requirement: engine must not leak oil.

Max. permissible oil consumption is 0.15 ltr./l00 km(1 quart per 390 miles).

Accurato consumption values arg determined by weighing.Drain engine oil at operating tomperature. Allow 5 minutesdrip time. Weigh and add specified amount of new engine oil.Drive car 1,000 km or 600 miles. Drain engine oil at operatingtemperature and weigh. Allow 5 minutes drip time. Engine oilspecific gravity at room temperature is approx. 0.9 kg/dm3.

Example: added oil - drained oil = consumed oil.45009 36009 =9009

900 : 0.9 = 1000 cc = 1 ltr. per 1000 km


1. Engine not broken in fully.2. Valve stem seals damaged.3. Pistons seized.4. Piston rings installed incorrectly, broken or worn.5. Excessive clearance between valve stem and valve guide.

€

ENGINE

11 11 ... Crankcase

CylindercBore diameter

Standard size mm (in.)

Special size mm (in.)

Oversize 1 mm (in.)

Oversize 2 mm (in.l

Surface finish Ra (pl

93.40 + 0.01 (3.6771 + 0.00041

93.45 + 0.01 (3.6791 + 0.00041

93.60 + 0.01 (3.6850 + 0.00041

93.80 + 0.01 (3.6929 + 0.00041

Max. out-of-true ofcylinder bore mm (in.)

bore mm (in.)

r 0.005 (0.0002)

0.01 (0.0004)

ENGINE

11 -804

s14 s38


Cylinder head height (new) mm {in.} 96.00 t 0.03 (3.7795 r 0.0012)

Combustion chamber volumewith valves and spark plugs cm3 (in.3l 43 r 0.5 (2.62 t 0.03)


Valve guide dia. - bore dia.Standard size mmOversize 1 mmOversize 2 mm

12.00x6-12.00H712.20x6-12.20H712.40x6-12.40H7

Total length mm {in.} 43.5 r 0.2 11.712 t 0.008) 4511.7721

Valve guide inside diameter(installed)

Standard size mmOversize 1 mmOversize 2 mm

7.0 H77.1H77.2H7

I nstal ling temperatureCylinder head oC (oF) + 150 {+ 300)

Valve guide oc {oF} - 150 l-2401

Valve guide protrusion mm (in.) 15 (0.5e01

ENGINE

11 12... Valve Seat lnserts

Valvs seat insert dia. - bore dia.(distance "D")Intake

Standard size mmOversize 0.2 mm (0.008") mmOversize 0.4 mm (0.016"1 mm

Standard size mmOversize 0.2 mm (0.008"1 mmOversize 0.4 mm (0.016"1 mm

40.15 96 - 40.00 H740.30 sG - 40.15 H740.45 s6 - 40.30 H7

36.15 sG - 36.00 H736.45 sG - 36.30 H736.75 s6 - 36.60 H7

Valve seat insert height - bore depth(distance "H")

Standard size mmOversize 0.2 mm (0.008") mmOversize 0.4 mm (0.016"1 mm

7.00-0.02-7.2Oto.017.15 - O.OZ - 7.351 0.017.3o-0.02-7.50 10.01

Installing temperatureValve seat insert oC (of )

Cylinder head oC (oFl + 150 (+ 300)

/ ' iI (

ENGINE

11 - 806

s14 s38

11 12... Valve Seats

Valve seat angle degrees 45

Gorrection angles degrees 35/60

Valve seat width (distance "8")lntake mm (in.l 1.2 + 0.1 (0.047 + 0.004)

Exhaust mm (in.l 1.4 + 0.1 (O.O5S + 0.004)

Valve seat dia. (distance "V"lIntake mm (in.) 36.6 + 0.1 (t .4.4-1+ 0.0041

Exhaust mm (in.) 91.4+ 0.1 ( t .236+ 0.004;

T\

Gamshaft bearingsBore diameter

Cam followersBore diameter

Tappet clearance

min (in.)

mm (in.)

mm ( in. l

11 12... Timing Case

3o.o I3:339 n.,81'' i3:3333,

37.5 l o'016 n.4764 + 0'0006)

0.025 ...0.066 (0.0010 ...0.0026)

fI cv

ENGINE

11 - 808

s14 s38

1121 ... Crankshaft and Bearings - Double Clasification -

Ground sizes of main bearing journalsStandard size red mm (in.l

blue mm (in.l

ss.oo :3:313 (2.1683 :3.333t, 60.00 : 3:313 es6z2 : 3:3333t

ss.oo :3.313 (2.16s3 :3:33??, 60.00:3:313 e.s62z _ 3:33?it

Undersize 1 red mm (in.l(0.25 mm/0.010"1

blue mm (in.l

il.ls: 3:313 (z.lbsb : 3.3333, be.7s:3:313 essz3 _ 3:3333,il.7s' 3.3i3 (2.15ss :3.331?, se.zs : 3:3i3 elszs : 3:33?i,

Undenize 2 red mm (in.)(0.50 mm/0.020"1

blue mm (in.)

s4.bo :3:313 ertsT :3.3333, se.so : 3:313 e.vizs : 3.3333rs4.so : 3:3i3 e.14s7 : 3:33?it be.so :3:313 e.s42s: 3:33??t

Undersize 3 red mm (in.)(0.75 mm/0.030")

blue mm (in. l

il.zs_ 3:313 (2.r3s8 : 3:3333, se.2s : 3:313 eas27 : 3:3331til.zs: 3.313 (2.13s8 : 3:33?1, se.2s : 3.3i3 els27 : 3:33i?t

Radial crankshaft bearing play mm (in.l 0.03 ... 0.07 (0.0012 ...0.0028)

t :

t

ENGINE

11 - 809

s14 s38

1121 ... Crankshaft and Bearings - Triple Glassification -

Ground sizes of main bearing journalsStandard size yellow mm {in.l

green mm (in.l

white mm (in.l

54.984 ... 54.990 12.16472... 2.16496) 59.984 ... 59.990 12.36157 ... 2.36181 I

il.s77 ... 54.983 |.2.164p,4... 2.1 64681 s9.977 ... 59.983 (2.36129 ... 2.361531

il.s7 1 ... 8t.976 12.16421 ... 2.164411 59.971 ... 59.976 (2.36106 ...2.361251

Undersize 1 yellow mm {in.l(0.25 mm/0.010") green mm (in.)

white mm (in.l

9.734 ... i l .740 (2.15488 ... 2.155111 59.734 ... 59.740 12.35173... 2.351961

u.727 ... 54.733 (2.15460 ...2.1il8p-t, 59.727 ... 59.733 12.3s14s... 2.35169)

il.721 ... il.726 (2.15436 ... 2.1 54561 59.721 ... 5,s.726 12.35121 ... 2.351 41 )

Undsrsize 2 yellow mm (in.l *.484 ... 54.490 (2.14503 ... 2.1 4527l, 5e.484 ... 5e.490 (2.34188 ... 2.34212l,I U

0.020"1 green mm (in.)

white mm (in.l

u.477 ... il.483 12.14476 ...2.1U991

il.47 1 ... il.476 12.14452 ... 2.1 M72l 59.47 1 ... 59.476 12.34414 ... 2.341571

Undersize 3 yellow mm (in.l(0.75 mm/ -0.030"1 green mm (in.)

white mm (in.)

il.234 ... *.240 {2.1 351 s ... 2.135421 59.234 ... 5e.240 |.233204 ... 2.332281

*.227 ... 54.233 12.13492... 2.13s15) 59.227 ... 59.233 12.33177 ... 2.33200)

il.221 ... 5,4.226 (2.13468 ... 2.1 3488) 59.221 ... 5e.226 (2.33153 ... 2.33173)

Radial crankshaft bearing play mm (in.l 0.020 ... 0.046 (0.0008 ... 0.0018)

(

ENGINE

11 - 810

s14 s38


Ground sizes of crankshaft thrustbearing journals

$tandard size mm (in.l 3o.o I3:33f {1.18r' I3:33?3,Oversize I mm (in.l 30.2 I 3:331 (1.,8e0 I 3:33?3,Oversize 2 mm {in.} so.a | 3.3!l n.,re6a l3:33?3,Oversize 3 mm (in.) eo.o | 3:3!f n.2o47+ 0.0025,

+ 0.0010'

Axial crankshaft play mm (in.l 0.085 ...0.174 (0.0033 ... 0.0068)

I

ENG!NE

11 - 811

s14 s38


Ground sizes of conrod bearing journalsStandard size mm (in.l 47.975... 47.991 (1.88877 ... 1.8S9401

Undersizel (0.25 mm/0.010"1 mm (in.) 47.725 ... 47.741 (1.87893 ... 1.879561

Undersize 2 (0.50 mm/0.020") mm (in.l 47.475 ...47.491 (1.86909 ... 1.869721

Undersize 3 (0.75 mm/0.030") mm (in.l 47.225 ... 47 .241 (1.85925 ... 1.859881

Radial conrod bearing play mm (in.l 0.03 ...0.07 (0.0012 ...0.00281


Ground sizes of conrod bearing journalsStandard size mm (in.) 47.975... 47.991 (1.88877 ... 1.889401

Undersize 1 (0.25 mm/0.010"1 mm (in.) 47.725 ...47.741 (1.87893 ... 1.879561

Undersize 2 (0.50 mm/0.020"1 mm (in.l 47 .475 ... 47.491 ( 1 .86909 ... 1 .869721

Undersize 3 (0.75 mm/0.030"1 mm (in.l 47 .225 ... 47 .241 ( 1 .85925 ... 1 .85s881

Radial conrod bearing play mm (in.) 0.020 ... 0.055 (0.0008 ... o.o022l

I

ENGINE

t l - 812

s14 s38

Max. permissible imbalance ofcrankshaft (dynamic, withoutflywheell gcm 10 25

Measuring planes on main bearings 1 and 5 - center bearingjournai

on main bearing 1 and 7 - center bearingjournal

Take-up on main bearing 1 and 5 on main bearings 1 and 7

Balancing speed rpm 500

Max. permissible runout oncenter main bearing journal(crankshaft running on outerbearing journals) mm (in.l 0.1 (0.0041

Crankshaft lift mm (in.l 84 I 0.1 (3.307 r 0.004"1

Max. permissible surface finishon bearing journals Bt (pl 2

ENGINE

11 - 813

Max. axial runout measuredon outside diameter mm (in.l

mm ( in. lMin. thickness of flywheel(distancs "A")


29.1 - 0.1 (1.146 - 0.Oo4l 26.6 - 0.1 (1 .047 - 0.0041

0.4 (0.016)

Diameter mm (in.) 12214.8031

Paint dot code

\6,

ENGINE

11 -814

s14 s38


Conrod big end dia. mm (in.) 52.000 ... 52.010 (2.04724 ...2.047631


Gonrod big end dia.Red mm (in. l 52.000 ... 52.008 (2.04724 ...2.047551

Blue mm (in.l 52.009 ... 52.016 12.04759 ... 2.047871

Conrod bushingOutside diameter mm (in.) 24.000 ...24.021 (0.94488 ... 0.94s71)

Inside diameter mm (in.l 22.020 ...22.024 (0.86693 ... 0.867081

Max. parallel deviation of conrodbores with bearing shells atdistancs of 150 mm (5.905"1 mm (in.) 0.04 (0.0016)

Max. displacement to one side degrees oo 30'

Max. weight deviation of conrodsin one engine (without bearingshells) g !4

Big end g +2

Smal lend g !2

\{E

ENGINE

11 - 815

s14 s38

11 25... Pistons Pistons and pins are matched - only replace together.

Waight class (dia-stamped or stamped) *or-(max. weight difference of all pistons: 10 grams)

ldentification on piston Piston diameter, arrow for installed direction, compression ratio

Piston diameter{checkpoinl"A"l

Standard size mm (in.l 93.35 (3.6751

Special size mm (in.l e3.40 13.6771

Oversize 1 mm (in.l 93.55 {3.6831

Oversize 2 mm (in.l 93.75 (3.691)

Piston running clearance mm (in.l 0.03 ... 0.06 {0.001 2 ... o.oo24l

Max. total wear clearance betweenpiston and cylinder(used engine) mm (in.l 0.15 (0.006)

\ qt

ENGINE

11 - 816

s14 s38


lst groove{plain compression ring}

Height mm (in.l 1.5: 3:313 (o.oseo : 3:3333rEnd clearance mm (in.l 0.30 ...0.55 (0.012 ...O.0221

Side clearance mm (in.l 0.06 ...0.09 (0.0024 ...0.0035)


Height mm {in.} '.u : 3:313 (o.oseo : 3:33i3,End clearance mm (in.l 0.30 ...0.55 (0.012 ...o.o221

Side clearance mm (in.) 0.06 ...0.09 (0.0024 ...0.00351

3rd groove(double-bevel ring with spring)

Height mm (in.l 3.0: 3:3ll (o.11Br : 3:3333,End clearance mm (in.l 0.25 ...0.50 (0.010 ...0.020)

Side clearance mm (in.l 0.02 ...0.05 (0.0008 ...0.00201

q

ENGINE

11 -817

s14 s38

11 31 ... Gamshaft

Drive double roller chain

Camshaft bearing dia. mm (in.) 3o.o - 3:333 (1.1sl' : 3:33?3,Camshaft bearing play

Radial mm (in.l o.o27... 0.053 (0.0011 ... 0.0021)

Axial mm (in.l 0.10 ... 0.15 (0.004 ... 0.0061

Cam distance "N" mm (in.) 43.71 11.7211

t'fv rE !

ENGINE

11 - 818

s14 s38

11 31 ... Chain Tensioner

Relaxed spring length mm (in.) 159 r 0.5 (6.260 r 0.0201

Chain tensioner piston dia.Stage 1 mm (in.l 19.462... 1 9.468 10.7662... 0.76641

Stage 2 mm (in.l 19.468 ... 19.474 (0.7664 ... 0.76671

Chain tensioner cylinder dia.Stage I mm (in.l 19.500 ... 19.507 10.7677 ... 0.76801

Stage 2 mm (in.l 19.507 ... 19.513 (0.7680 ... 0.76821

t.I t6

ENGINE

11 - 819

s14 s38

1134.. . Valves

Valve clearancelntake and exhaust valves

At max.35o c (gso F)coolant temperature mm (in.) 0.26 ... 0.35 (0.010 ... 0.0141 0.30 ... 0.35 (0.012 ... 0.0141

At operating temperaturs(thermostat operated) mm {in.l 0.34 . . .0.39 {0.013 . . .0.015) 0.3s . . .0.40 (0.014.. . 0.0161

Min. edge thickness of valve headMachining limit (distance "A")

Intake mm (in.lExhaust mm {in.}

0.50 (0.02010.95 (0.037)

Head diameter (distance "T"llntake mm (in.lExhaust mm (in.l

37 - o.r 11.457 - o.oo4)32 - o.t (1.260 - o.oo4l

Stem diameter (disunco "S"lStandard size mm (in.lOversize 1 mm. (in.lOversize 2 mm (in.l

7.O 10.276l7.1 lo.z7el7.2l0.283l

Max. wear clearance betweenvalve stem and valve guide{tilt clearance "K")

Intake valves mm (in.lExhaust valves mm (in.l

0.65 (0.02510.80 (0.0311

q q\t

ENGINE

11 - 820

s14 s38

11 40... Oil Supply

Lubricating system forced oil circulation lubricating system with pressure control valve in filtered oil circuit

Oilgrade see Service Information of Group 00

Total oil volume ltr. (pts,l 4.4 (e.3) 5.75 (12.1)

With oil cooler {only fillafter repairing) ltr. (pts.) 4.95 (10.5) 6.5 (13.71

Oilvolume in oil filter ltr. (pts.l 0.30 (0.6) 0.75 (1.61

Oil consumption (see page 00 .31in liters (pints)/l00 km (62 milesl max.0.15 (0.321

11 41 ... Oil Pump

Oif pump design Eaton system rotor oil pump

Oil pressureat idle speed bar (psil 0.5. . .2.O 17.. . 14)

at top speed bar (psi) 4.0. . .6.0 (57 . . . 851

\t'

h

ENGINE

11 *821

s14 s38

1152... Fan Clutch

Design temperature and speed controlled visco fan clutch

switching-on tsmporature oc (or) 90r4(r95r7l 82r.4{180r7}

Switching-off temperature oC (of l \ 45 (113) \ 60 (140)

FanDiameter mm (in.) 400 (15.748) 420 (16.535)

Number of blades 8 I

Speed at 3500 rpm engine speed{clutch switched on) rpm 2000 r 100 2400 r 100

11 53 ... Thermostat (Coolantl

Opening tempsrature(stamped in thermostat) oC (of) approx. 80 (175)

.,i\.

' t

ENGINE

Tightening Torque

Main bearing caps

Step 1Step 2 (torque anglel

Braces

Coolant drain plug incrankcase

Washed and lubricated with oil.

M 10 = 4-cylinder ' -/M 20 = 6-cylinder smallM 21 = Gcylinder.small dieelM 30 = 6-cylinder largeS 14 = 4cylinder M-PowerS 38 = Gcylinder M-Power

Nm (ft. lbs.l

M10M10M10

M10

M14

M 10/M 20/M 30M21s 38/S 14

M21

AI

58 ... 63 142 ...45160+7(44+5122.5 t 2.5 (16 t 1.5150r30

43!4 (31 t 3)

50+6(36+4)

t 't ,

1112.. .Cylinder head bolts

Step 1

Step 2 (torque anglel

Step 3 (torque anglal

Washed and lubricated with oil.Tightened crosswise from middle to outside.

f

t

60r2(43r11

wait 15 minutes

33t30

run engine warm25 minutes

25r50

11 -Ala ENGINE

Tightening Torque Type | ru, (ft. tbs.l

11 -A1b ENGINE

Tightening Torque

: .

Nm (f t . lbs.)

40+5(29+4)

wait 15 minutes

60+5(43+4)


25*5()

Washed and lubricated with oil.Tightened crosswise from middle to outside.

€/ i ,v / - '

:v

11 12.. .Cylinder head bolts

Step 1



Washed and lubricated with oil.

^ Tishtened crosswise from middls to outside.

55r5(40r4)

wait 15 minutes

73 t30


g0r 50

11 -Alc ENGINE

Tightening Torque Tvpe I tum (ft.lbs.)

11 _Ald ENGINE

Tightening Torque Nm (ft. lbs.l


Step 3 {torque angle)

Washed and lubricated wath oil.Tightened crosswise from middlo to outside.

60 r 2 (43 r 1)

wait 15 minutes

33i30


35r5()

((.:\ l

Cylinder head bolts

Step 1

Step 2

Step 3

Washed and lubricated with oil.Tightened crosswise from center to outside.

M12 s 38/S 14

50 r2 (36r 1)

80t2{58 r1)

Wait 15 minutesl

100 r 2172t 11

11-A10 ENGINE

Tightening Torque Type I ttr (ft. tbs.l

(\

11- A2 ENGINb

Tightening Torque Nm {f t . lbs.}

Suspension holder on cylinder head M I

Cylinder head cover M 8

Oil trap on cylinder head cover M 8

Timing case on cylinder head M7

M8

Coolant pipe on rylinder head M 6

Pf ug for rear coolant pipo M 22x1

Plug for oil pressure bore M 14x1

M 20lM 21

M21

M21

s 14lS 38

s 14/S 38

s 14lS 38

s38s14

22 !2 (16 11)

15 r 1.5 (11r 1l

17 t2 (121 1)

15 !2 (11 r 1)21 t1(1510.5)

11 r1(810.5)

35r5(25131

33r2124t1l-25t3(1812)

t \

11 13.. .

1114 . . .

1122 . . .

Oildrain plug 17 mm

19 mm

Oil pan to crankcase and timingcass covgr

Upper and lower timing casecovers

Front/rear gnd covers to crankcase

Flywheel to crankshaft(replace expansion bolts - usemicrooncased bolts or installbolts with a bolt camentril

M 10/M 30/S 14lS 38M 10/M 30/S 14lS 38

33+3|.24+2159 ...64 (43 ...461

e . . . 11 (7 . . . 8)

I . . . 11 (7 . . . 8)22 *2 (16 r 1 l

9r1(6.510.5122 !2 (16 t 1)

105 17 (76 t 51

M12

M6

M6

M8

M6

M8

M12

Type | *m (ft. tbs.l

11-A3 ENGINE

Tightening Torque

*'Source: HWB

Nm (ft. tbs.l

Pulley to crankshaft

Vibration damper hub tocrankshaft*

Pulley/vibration damper tovibration damper hub

t Washed and lubricated with oil.

M 20lM 21M 30/S 14/S 38

M 20lM 21lM 30/S 38

190 r 10 (137 t 7)

410120{.297 ! 141uo ! 10 (318 t 7)

22 !2 (16 t 1)

(.a

l 't

rq

11:A5 ENGINE

Tightening Torque Type I Nm (ft.lbs.l

Conrod bolts

Gonrod boltsStep 1


Conrod bolts- classified bearing shelts (withpaint color codesl -Step 1

Step 2


M11

M 10/M 30

M 20lM 21

52.. .57 (38 . . .41)

20 (14.51

7oo

10 (71

30 (21.51

60+20

- A 5a ENGINE

Tightening Torque

LI

Nm (ft. lbs.)

DME adaptor to camshaft

Sprocket to camshaft

Bearing cap to camshaft

Tensioning wheel holder tocrankcase

DME adapter to camshaft

Sprocket to camshaft flange

Sprocket to camshaft

Flange to camshaft

Plug for chain tensioner

Cylinder for chain tensioner piston M26x1.5

M20

M 20lM 21

M21M 21lS r4ls 38

M zAlM 21

M 30/S 14lS 38

M 10/M 30

s 14/S 38

M30

s 14lS 38M 10/M 30

s 14lS 38

60r5(43r31

65...70 (47 . . . 501

9r1(6.5r0.5122 t2 (16 r 1 l

22 t2 (16 t 1)

23 t1 (16.5 t 0.5)

7 (51

9+1(6.5+0.51

142!5(10313)

40 t2 {29 r 1)35r5(25r31

50 !2 (36 t 1)

q

11 35 . . .

11 40 . . .

Bolt in rocker arm

Clamping bolt in rocker arm

Sprocket to intermediate shaft

Oil presure switch

Plug for pressure relief valYe

Oil pump to crankcase

Oil pump to cover

Sprocket to oil pump

M 10/M 201M30

M21

M 20lM 21

M 10/M 201M211M30s 14lS 38

M 10/M 30M20

All

Atl

M 10/M 30M 10/M 30/S 14/S 38

10r1(7.0t0.5)

8t1(6.0r0.51

60ts(43r41

30 ...40 122 ...29l-17 . . .23 (13.. . 16)

35 ...40 .25 ...29125 ...30 118 ...221

22 t2 (16 r 1)

9t1(6:5t0.51

9r1(6.5t0.5125 ... 30 118 ...22t-

M6

M6

M 10.9

M8

M6

M6(use 12x8x l shim behind M l0x l nutsprocket only for M 10 oilpumpl)

11-A6 ENGINE

Tightening Torque Type I wm (ft. tbs.)

11 - A7 ENGINE

Tightening Torque

I

a

Nm {ft. lbs.)

Filter (throw-away cartridge)

Full flow oil filter

Oil filter housing to crankcaseM8M8

Oil filter drain plug (hollow)(solid aluminuml(solid in insertl

Camshaft lubricating oil pipe oncylinder head (hollow boltl M I x 1

Oil spray jet to crankcase

Oil cooler pipes to oil filter housing

Oil pipes to turbocharger M I

Oil pipe from turbocharger tocrankcase l22mm hollow boltl M 16

Oil pipe to turbocharger {hollow Bolts}(coupling nuts)

M 10/M 201514

M21M30M 30/S 38

M 10/M 20M20825M 21lM 30/S 38

M 21lS 38M21M21

M 10/M 30M20

M21

M20lM 21lM 30/S 38

M21

M21

M30

tight as specified

1 . . .25 (16 . . . 18)!5122!31.. .33 (20 . . .23t .

. . .26|-17.5. . . 1e)t 5 (291 3). . .24114.s. . . 17)

+ 3 (14.5+2110+317+21

+2 .17+11

11 . . . 13 (8. . .9). . .8 (4.5. . .5.51

r 1 (6.51 0.5)

30 ... 40 (22 ...291

22 t1{16 * 0.5}

40 15 (291 3)

25 . . .28 (18 . . . 20130 . . .33 (22.. .241

q :

1151 . . .

1152 . . .

11 53.. .

Water pump to crankcase

Fan clutch to urator pump(nut with left-hand threadsl

Fan to fan clutch

Pulley to water pump

Temp. transmitter/temp. switch

Thermostat housing

Bleedor icrow

M 10/M 201M211M30

M 20/M 211M30

M 20lM 211M30

22 t2 (16 r 1 l9t1(6.5r0.5)

40 + 10 129 +71

9t1(6.5r0.5)

9r1(6.510.5

18r1(13r1)

9t1{6.5r0.51

6.. . 10(4.5. . .7.01

M8M6

M6

M6

M14

M6

M8

11-A8 ENGINE

Type I Nm (ft. tbs.l

(\

!I

11-A9 ENGINE

Tightening Torque Nm (ft. lbs.)

11 66 . . .

1170.. .

1178 . . .

Intake manifold to cylinder head

Exhaust manifold to cylinder head(upper row of staybolts installedwith bolt cementl

Retightened after 1200 miles

M6

Vacuum pump M 6

EGR valve to exhaust manifold

Oxygen sensor(threads coated with "Anit-seize"l * *

*t Source: HWB, No. 81 22 9 400 088

M 10/M 201M30M21s38s 14lS 38

M 10/M20l M 30

M21

M21

s 14lS 38

M21

M21

Atl

30 ... 33 |22 ...24!,20 . . .24(.14 . . .17l ,20 . . .24114 . . .17l ,9. . . 10 (6.5 . . .7.01

30.. .33 122.. .241

20.. .24 (14.. . 171

10 . . . 12 ( 7 . . . e}

I . . . 10 (6.5 . . .7.01

9r1(6.510.5)

30 !2l22t 1l

55r5(40r3)

i ,v

Rubbor mount to front axlecarrier

Rubber mount to bracket

Bracket to engine

M8

M10

M10

M8

M10

Ail

Ail

Atl

Atf

Atl

25. . .28 (18.. .201

€.. .48 (31 . . .3s)

43 . . .48 (31 . . .35)

22 . . .24 (16 . . . 171

43.. .48 (31 . . .351

11 -A1O ENGINE

Tightening Torque Tvpe I rum (ft. tbs.l

12 ENGINE E LECTRICAL EOUIPMENT

Page

Distr ibutor . .12- 1Distributor rotor - 1Position senderSpark plugs . 3Resistors in secondary circuit - 3fgnit ioncoil . - 4Gontrol units for TCI and DME . 5Speed and refarence mark senders"g 5Heating time control unit . . .'. . . 6Heaterplugs. - 6AlternatorShielded capacitor 7Temperature switch (idle control) IDrive belt - 8Voltage regulator - 8Starter r . r . . . - ISolanoid IOil pressure switch - 10Oil level switch - 10

12 11

from 1987models on

Page

12 -20-20-20

!-22-23,:

-24

:

-24-25-25-26

-26

:

:

12

1314

212331

3241

61

62

63

Temperaturo gage (transmitter and contact switch)Temperature sensor for heating time control . . . .

- 11- 11

TemperatureswitchforEGR.. . . . -11Tompsraturo sensor for vacuum adyance control - 12Temperature ssnsor for air conditioner - 12Temperaturo sonsor (VP-20 fuel injectionl . . . - 12

81 Coolant heater - 12

tIv \

ENGINE E LECTRICAL ECUIPMENT

12-1

a)b)

318 i318 iA

a) 524 td A

t -I

al 528 elA I u) 533 i/Ab) 325 elA I b) 535 i/A

a)b)

633 CS|/A635 CS|/A

a)b)

733 ilA735 alA

12 11 ... Distr ibutor

Code no.

since 11/83

o 237 002 080

o 237 002 096

Coil resistance k-ohm 1.1 x 10% digital motor electronics

Glearance between stator androtor teeth mm 0,3 . . .0,7

1211 ... Distr ibutor Rotor

Resistance k-ohm 1t20% 1! 20%

: ,{,\

t . .FIl

- - \q

ENGINE E LECTRICAL EOUIPMENT

12 -2

alb)

318 i318 iA

a) 524 td A alb)

528 elA325 elA

alb)

533 i /A535 i/A

a)bl

633 CSi/A635 CS|/A

a)b)

733 a/A735 i/A

12 11 ... Position Transmitter

Resistance measured betweenlines ohm 80r10

at temperature oc (oFl 2315(73r9)

Resistance between line andshield kohm >60

$-Y

ENGINE ELECTRICAL EOUIPMENT

12-3

a)bl

318 a318 iA

a) 524 td A alb)

528elA I r l 533i /A325 elA I bl s35 i/A

a)bl

633 CS|/A635 CS|/A

alb)

733 i lA735i lA

12 12... Spark Plugs

Bosch Type WR9DS WR9LS

Beru (without shielded resisterl Type RS33r

Electrode gap mm (in.) geiS;l .0., + 0.1 (0.028 + 0.0041

Shielded resistor k-ohm 6r3

12 12 .., Resistors in Secondary Circuit

Shielded plugs(on ignition coil and distributorl k-ohm 1t20% 1t20%

Spark plug end caps k-ohm 5 t 2to/o 5 ! 20%

I tq. .


12-4

a)bl

318 i318 iA

a) 524tdA alb)

528 e 19325 elA

a)b)

533 i/a535 i/A

alb)

633 CS|/A635 CS|/A

a)bl

733 ilA735i,|A

1213 . . , lgni t ion Coi l

Code number O 221 ... . .122319 a) . . .122032albl since3.83.. . 118335

a) . . .122032

.. . 118 335b)

Primary winding resistance ohm 0.82 0.5

Secondary winding resistance kohm 8.25 6.0

Primary inductivity mH 5.6 3.7

Secondary inductivity H 31 31

Color of label gray a) l ight blue

bl yel low

I. t

I


12-5

a) 318 ab) 318 iA

81 524 tdA al 528 elAbl325 elA

al 533 i/Abl535 i /A

a) 633 CS|/Ab)635 CS|/A

al733 ilAbl735 i /A

1214 ... Control Units for TCI and DME

TCI{transistor coil ignition systeml

Code number

o227 100 111-sin"d {zieq- -

1 705 607/608

DME(digital motor electronics) see Group 13 61 ...

12 14... Reforonco Mart Trrnmittcr , , ,

R6.irtrnc6 of coil rt | | |23r5oC(Bi9oF) ohm | - 180110 | 960110%

B€tirtancs botwosn | | |coi land.hiold k-ohm | - l \50 | S100

12 14 ... Spo€d Tranrmittor , .T-T--

R.riitsncc of coil ohm | | 960 r 10 96

lnsulation ro6ittance k.ohm | | \100

Speod tnnrmitt.r di.tanc6 mm{in.) | | 1.3t0.1 |I lo.05rjr.004) It t t

Altornating voltago.t idlo | | Iroeed v I l> 1.4 |

r l


12- 6

al 318 ib)318 aA

al 524 tdA

..,'l':

' t4t:i

al 528 elAbl 325 elA

a) 533 i/Ab)535 i/A

al 633 CS|/Ab) 635 CS./A

al733 ilAb)735 i /A

1221 ... Heating Time Control Unit .,{:ii

Fuse A 80

Heating time in seconds forcoolant tomperature sec./oC(oF) 7..J.5/-t0(+t4l

6...8.0/ 0(+3214.."6.0/+25 (+771

Safety srruitch-off after sec. 8+5

12 23 ... Heater Plugs

Temperaturo after 5 seconds oc (or) |heating time I

Testing voltage V -l

Power input for one heatar plug -l

after 5 seconds of operation at Izoo c (oao r) e IHeater plug resistanc€ at

_l

2ooc (680 Fl ohm IPower input of all heater plugsafter 5 seconds of operation at Izooc (680 Fl A I

=

=

-]

t *r rt**0 100221 133

750.. .800(1385 ... 14701

12.5

13.. . 15

0.4. . .0.6

60.. .80

IIII

IIIII

II

III

IIII

II

III

\11, . I ! ' : \


12 -7

albl

318 i318 iA

524 td A a! 528elA I u l 533i /Ab) 32s etA I b) s35 i/A

a)b)

633 CS|/A635 CS'/A

albl

733,/A735 ilA

1231 ,..Alternator

Nominalvoltage V 14

Max. current A 65/80

Max. power W 910/1 120

Min. diameter of slip rings mm (in.l

Min. carbon protrusion mm (in.)

1231 ... Shielded Gapacitor

Capacitance pF

28 (1.1021

5.0 (0.197)

2.2 t 2O Yo

t.Il \

ENGINE E LECTRIGAL EOUIPMENT

12-8

a) 318 ib)318 iA

al 524 tdA al 528 elAbl 325 elA

a) 533 i/Ab)535 i/A

a) 633 CS|/Ab)635 CS|/A

al733 ilAb)735 i /A

12 31 ... Drive Belts

Open flank belt sizo mm 9.5 x 865 9.5 x 995 a) 9.5 x 950since 5.839.5 x 965

b)9.5 x 965

a)12.5 x 1055b)l2.5 x 1040

12.5 x 1055

Belt tightness see Repair Manual Group 1231 .,.

12 32 ... Voltrgo Rogul.tor r

Rogulating voltlgs at ongine.poed ol 1500 rpm and appror, I5 .mpt ch.rging cun.nt 8! wgll Iar 30 to 600 c (86 to 1400 Fl Ion voltage rceubtor V

, I 13,5 ... 142

12 31 ... Tsmp€raturc switch (for ldl.Sp.€d controlVDOI

switchincoff tcmpo.ature oc(oF) | 01rt32rZ)

Svritching on tompol.turo I{with droppino tompor.turo} oc loF} I 5 {9} b€low rwitching"off t€mporatu.; not lat r than - 8o c (+18o Fl

Colorcods I yollow

swirchinq.on r.rDporaturc oc {oFl I ota 3(1t3t 5} |

t*,M(with dropping tomp€raturo) oc loFl | 30 (86) at tho tatoit

(qt


12-9

a) 318 ib)318 iA

a) 524 tdA al 528 elAb) 325 e/A

al 533 i/Ab) 535 i/A

al 633 CSi/Ab}635 CSi/A

al733i/Ab)735 i /A

12 41 ... Starter

Testing voltage V 12.5

Nominal power kW 1.1 2.2 1.1 1.5

Axial play of armature mm (in.l

Min. carbon brush length mm (in.)

0.1 . . .0.2 (0.004.. . 0.0081

13 (0.5121

No. of pinion teeth/modules 912.5 9112.54 912.11 912.5

Max. power input at 2Oo C(680 Fl - battery charged A 230 see Nominal Value Microfiche - Engine Test

12 41 ... Solenoid

Polrv.] draw !t iorm.so | | |(rt nominal Yolt to) | | |

Pull ins.nd holdine coll A l{o 151 | /o

Hotdin! coll A 17.5 19.5 | 7.5

I


12- 10

a) 318 ib)318 iA

al 524 tdA al 528 elAb) 325 e/A

a) 533 i/Ab)535 i/A

a) 633 CS|/Ab)635 CS|/A

al733 i lAb) 735 i/A

1261 ... Oil Pressure Switch

Switching-on pressure bar (psi) o.2 . . .0.5 (3. . .7)

12 61 ... Oil Lor,6lSwitch (Dynamic)

Rorirtanco (m.8rur€d on dii- I Iconnsct d pluo ard ground) , | |

Dynamic on conn.2. I lonconn.3(whits wiro) | |

Lovelokay k-ohm I | 1x1%

Lwol too low ohm I | 0 ...0.2

static on conn. 1 | lonconn.z(blue/violet wirel | |

Lovolokav ohm I | 0...0.2

Level too low ohm I I €

I

ENG INE E LECTRICAL EOUIPMENT

12-11

al 318 ib) 318 iA

al 524 tdA al528 elAb!325 elA

a) 533 i/Ab) 535 i/A

al 633 CS|/Ab) 635 CSI/A

al733 i lAb}735 i /A

1262 ... Temperature Gauge for Temperature Transmitter (Coolantl

Resistance between connectingplug and ground(see engine wire diagram forwire colors)

og

206090

op

68140194

Ohms677 r 84134 r 13.551.2 t 4.3

Switching tomporaturo forwarning lamp oc (of) 118r31244t51

12 62 ... Temperature Sensor for Heating Time Control

Resistance between connectingplug and ground (see RepairManual for connectionsl

at 200 c (68() F)at 3oo C (86() F)at 600 c (140() Flat 900 c (194(, F)

ohmsohmsohmsohms

1 134 r 125704 r 66272t 27114r 11

12 63 .,. Tomp.nturo Switch for EGR

Color codo I I whitowith II |nng I

switchineon totuperlrr.o oc (oF) | lzeta I{with ri.ino temp€raturol | | 1172 t5l I

Switchineoff tomForaturr oc(oFl I leOtg I| | (1401 5) |

!

t .t


12-12

a) 318 ib)318 iA

al 524 tdA al 528 elAbl 325 e/A

al 533 i/Ab}535 i /A

a) 633 CS|/Ab) 635 CSI/A

al733 ilAb)735 i /A

1262 ... Temperatura Sensor (in Air Cleaner)for Vacuum Advance Control

Resistance at 10 to 38o C(50 to 1o0o F) ohm 950 r20

12 63 ... Temperature Switch for Air Conditioner (on Cylinder Headl

Opening temperature oC (oF)(with rising tempsraturo)

108r21226 t4l

Closing temperature oC (oFl e8 13{zoal $1

Golor code black withgroove

1262 .,Tomperature Sensor for VP-20 Fuel Iniection (on Gylinder Head)

Resistance at 2oo c {680 F} k'ohmat700 c (1580 F)

2.4. . .3.O0.4. . .0.5

1281 ... Coolant Heater

Operating voltage V - 12O

Power w soo 1?o %

Power input at zooc (68oF) A 4 t10%

Resistance at 20o c (680 Fl ohm 28 t2

\ i .iq


12-20

from model 1987 on

'3 'Series

E30

'5'Series

E28

'6'Series

E24

'7'Series

E32

1211 . . .

Distributor rotor k-ohms 1t 20%

Angled/shielded connectors kohms 1!20%

Spark plug connectors k-ohms 5 ! 2Oo/o

Position senderat250 C (770 Fl

Coil resistance ohms 80r 10

lnsulation resistanco kohms >60

tt

tt

Cylinder identifying senderCoil resistance at2oo c (680 Fl

Spark plugs

Electrode gap

M-types

BoschBeruChampion

ohms

mm ( in. l

mm {in.}

1l2l3)


12-21

from model 1987 on

'3'Series

E30

'5'Series

E28

'6'Series

E24

'7'Series

E32

WR 9 LSl)M3: gMS: lme:xEDTcl) lXsDcl) x 5 DCl)

A 6 c3) lao c3)

W 8 LCRI}

0.7 + 0.1 lO.OZt + 0.0041

0.6 + 0.1 lO.O24 + 0.004)


12-22

from model 1987 on

'6'Series

E24

'5'Series

E28

o 221 118 335lgnit ion coil

Code number

ResistancePrimary

Secondary

InductivityPrimary

ohms

k-ohms

mH

HSecondary

(.t


12-23

from model 1987 on

3'Series

E30

'5'Sgries

E28

'6'Series

E24

'7'Series

E32

1214 , . .

Pulse senders (reference markand speed senders)

Coil resistance ohms 960 r 10% ilor 10%

DME (Digital Motor Electronicsl see 13 61 in Group 13

t\ \rI

\


12-24

from model 1987 on

'3'Series

E30

'5'Series

E28

'6' Series l'7' SeriesI

E24 leSZ

1231.

AlternatorRated voltage V 14

Rated current A 65/80/e0

Max. power W 910/112011260

Narrow drive belt size mm 9.5 x 965 528 e:9.5 x 955535 i, M 5:12.5 x 1055

12.5 x 1055

\la

\


12-25

from model 1987 on

'3'Series

E30

'5'Series

E28

'6'Series

E24

'7'Series

E32

12 32... Voltage Regulator

Regulating voltage at 1500 rpmengine speed and electric con-sumers switched off. with temp.of 3o to 600 c (86 to 14oo F)on regulator 13.5 . . . 14.2

12 41 ... Starter

Rated power KW 1.1M 3: 1.4 I 535 i , M 5:1.5

1.5

Testing voltage V 13 + 0.2

Axial armature play mm (in.) 0.1 ...0.2 (0.004 ... 0.008)

Ir tt

I

\


12 -26

from model 1987 on

'3'Series

E30

'5'Series

E28

'6' Series l'7' SeriesI

E24 lE32

12 41 ... Solenoid Switch

Power consumption at term. 50(at rated voltage)

Pulling and holding coil A 40

Holding coil A 7.5

1261 ... Oil LevelSwitch

Resistance (measured ondisconnected plug againstground)Conn.2 dynamic

Level okay

Level too low

Conn. 1 staticLevel okay

Leveltoo low

Wire Colorwhite

Resistance1k-ohmtl%

0 . . .0.2 ohm

0 . . .0.2 ohm

oo ohms

blue/violet

q


Tightening Torque {ft. lbs.l

1212.. .

1214 . . .

Distributor

Distributor rotor to adapter

Spark plugs (unlubricatedl

TCI control unit

Speed and reference mark sensors

Heater plugs

Wire on heater plug

M10

M?OIM 30 with DME

Allexcept M 21

318 i

Al l with DME

M21

M21

8 . . . 10 (6 . . . 7)

2.8 t0.z12! 1l

20 . . .30 (15 . . .211

2.. .2.5 (1.5. . . 1.8)

7t1(5r0.5)

25 15 (18 r 41

4.. .5 (3 . . .4)

i \

12 31 . . .

12 41 . . .

1242.. .

Pulley to alternator

Pulley to alternator sinco 1986 models(rotor shaft with hexagon socketl

Conn.B*onalternator

Conn.Dionalternator

Starter mounting bolts

Battory lead to starter

Battery lead to battery- all metalterminal- plastic terminal

M8

M5

35 + 10 125 +71

50+5(36+41

7.5. . .8 (5 . . .61

1.6 . . .2.3 (1.16 . . . 1.66

47 . . .50 (34.. .361

I ... 12 (6 ... 9l

5.5 r 0.5 (4.0 r 0.311 . . . 1.5 (0.7 . . . 1.11

12 * A2 ENGINE ELECTRICAL EOUIPMENT

Tightening Torque Type I nm (ft. tbs.l

tq \.?

II

12- A3 ENGINE ELECTR ICAL EOUIPMENT

Tightening Torque lbs.l

12 61 . . .

1262.. .

Oil pressure switch

Temperature transmitter

Temperature switch on cyl. head

Temperature switch on fuel filter

Temperature switch on water flange

Temperature switch 0o / 45o C

Heating element on fuel filter head

Ail

Al lexcept M 21

M21

M21

M21

Allexcept M 21

M21

25r5(18r4)

20l14l

17 . . . 19 (12.5 . . . 13.5)

17 . . . 1e (12.s . . . 13.51

17 . . . 1e (12.5. . . 13.5)

25 ... 30 118 ...221

0.8 . . . 1.2 (0.6 . . .0.851

\q\ i

13 FUEL SYSTEM

Models with Gasoline Engine Page

Control unit for idle regulation . 13 - 1Pressurg regulator 2Control unit . 3Air flow sensor - .4Pressure sensor ICoolant tempsrature sensor - 10Temperature timo switch - 11Throttle switch - 12Fuel injector.. . . - 13Electric start valve - 15

524td Turbo Diesel

Fuef supply . 13 - 20Fuel heat ing . . . . -2ODistributor inlection pump/testing and adjusting values - 21Shutoff valve (fuel feed) . - 22Timing valve for injection pump VP-20 - 22Coolant temperature sensor (VP-201 - 22Fuel in jecto6.. . -23Gontrol unit for injection pump VP-20 - 23

13 4113 5313 6113 62

626262

13 6313 64

64

13 3113 3213 51

5151

13 6213 5313 61

' l--

\ \(

' l

FUEL SYSTEML-Jotronic

13 - 1 from model 1983 on

al 318 i/Abl318 i /A

al 325 elAb) 32s i/AclM3

al 528 elA al 533 i/Ab) 535 i/AclM5

1., usa csi/A

l3 fi13 cs /A 733alA

735i lA735ilA-E32

13 41 ... Gontrol Unit for ldle Regulation

Code number 4r22021009100r4r220210031001b, c) :0 280 140 509

41220210031001412.20210031001b, c l :0 280 140 509

412.20210031s01b, cl :0 280 140 059

412.20210031001b, c l :0 280 140 509

Air condition speed rpm 850 r 50 850 r 50b, c l : -

850 t 50 850 t 50b, c l : -

850 r 50b, c): -

850 t 50b, c l : -

Warm-up speed rpm 950 r 50 950 r 50b, c) : -

950 t 50 950 r 50b, c l : -

950 r 50b, c l : -

950 r 50b, c l : -

Nominal speed rpm a) 850 t 50b) 750 r 50

al 700 t 50bl 720 r 40cl 880 t 40

700 t 50 al 700 t 50b, c) :800 r 50

al 700 t 50b, c l :800 r 50

al 700 t 50b, c) :800 r 50

13 42... Drivs Motor

Code number f08202/006/005408.202/003/001408202/003/0014s8202100u002bl0 26t 200059t214 r705 019.9

408.202100I002bl0 26t 200 059t2t4 1705 619.9

408.202100u002bl0 20r 200 059t2t41705 6t9.9

\sq

Code number

Part number

Nominal pressure

Regulating pressure

bar (psi)

bar (psi)

FUEL SYSTEML-Jetronic


a) 318 i/A al325elAbl325 ilAc)M3

al 528 elA al 533 i/Ab) 535 i/Ac)M5|

) 633 CS|/Ab) 635 CS|/Ac)M6

| 733 i lA1735 i lA| 735i,|A-E 32

13 53 ... Pressure Rogulator

a)0 280 160 226a). . .1 2U 796.9

a)0 280 160248a). . .1711 Arc.gb, c)0280 160249b, cl. . .1711 541.9

a)0280 160225al. . .1284 796.9

al0280 160225a)...1 284 796.9bl0 280 160226bl. . .1284 897.9c)0 280 160 249c). . .1711 At l .9

a)0 280 160 225a). . .1284 696.9b)0 280 160 226b)...1 284 897.9cl0 280 160 249cl.. . 1 711 541.9

al0 280 160225al. . .1284 796.9bl0 280 160 226bl... 1 284 879.9cl0 280 160 249cl. . .1 711 541.9

al 3.0 t 0.06(43 t l )

al2.5 t 0.05(36 t 1 l

b,.c)3.0 r 0.06(43 r 1)

al2.5 t 0.05(36 t 1 l

al 2.5 t 0.05(36 t 1 l

b, c)3.0 t 0.06(43 * 1l

a) 2.5 t 0.05(36 r 1l

b, c)3.0 * 0.06(43 r 1)

al 2.5 t 0.05(36 r 1)

b, cl3.0 r 0.06(43 r 1)

al2.8 . . .3.2(40 . . .471

al2.3 . . .2.7(33 . . .381

b, c)2.8. . .3.2| .40 . . .471

al 2.3 . . .2.7(33 . . .38)

al2.3 . . .2.7(33 . . .381

b, c)2.8. . .3.2(.40 :..47!.

a l 2.3 . . .2.7(33 . . .38)

b, c)2.8. . .3.2(40 . . .471

al 2.3 . . .2.7(33.. . 38)

b, cl2.8. . .3.2140 ...47l-

((



of data plate

See parts microfiche forion numbersl

al 533 i/Abf 535 i/Ac)M5 )735i /A

| 735 ilA-E 32

al 325 elAbl325,lAc)M3

al 528 elA 633 CS|/Abl635 CS|/Ac)M6

13 61 ... t1214...1 Control Unit

Coasting cutoff speed (engineat operating temperaturel

al 0280 001 310...r 277 610.9) t2.840280 00t 328... | 706 0773

al 0261 200021... | 286 047.9\ 10.840261 200 027

bl 0 26t 200 t53... | 7t4 998.9

cl 0261 2000t1... | 307 482"9

a) 0 201 200 00t... | 273 269.9\ t0.840261 200027

al 0261 200 00s... | 277 562.9

bl 0 20t 200 05e... | 705 619.9

cl 026t 200 079 lc) 0Z6t 200 tS||... | 309 799.9 | ... | 718 807.9

II

Ial 5000 t80

cl 7200 r80

al 6400 t80bl 6400 r 80cl 68001 80

IIz.\



a) 318 i/A al 325 elAbl 325 il AclM3

al 528 elA a) 533 i/Abl535 i/AclM5

a) 633 CS|/Ab) 635 CS|/AclM6

tl733 ilAb) 735 i/A;) 735 ilA-E 32

13 62... Air Flow Sensor

Code numberPart number

0 280 202 039... | 279 664.9

al 0 280 202 066... | 705 72r.9

bl 0 280 202s82... | 280 615.9

c) 0 280 203 028... | 307 486.9

0280202029...r 2732385

a) 0 280 203 016... | 277 564.9

bl 0280 203021... | 286 064.9

cl 0 280 203 025... r 307 019.9

a) 0 280 203 Oto... 1 277 054.9

bl 0280 203027... | 286 064.9

c) 0280203025... | 307 019.9

a) 0 280 203 016... | 277 564.9

b) 0280203027... | 280 004.9

c) 0280203027... | 286 064.9

Color code yellow a) blackbl redc) green

al brownb) bright redcl-

al brownbl bright redc)-

r) brownbl bright redc) bright red

\E

FUEL SYSTEM

13-5

Air Flow SensorWiring Diagram / ConnectionsUniversal Test Adapter

BMW Service TesterM 13 with 500 HeruM 02 test value

w

Sensor plate closedCode no. (FD) A nominal value (Vl

FD = date of manufactureTesting temperature =18.. .250 C (65 . . .770 Fl

0 280 203 016 ( - I e 0.11 ... 0.12 0 280 202 039 ( - l a 2.90 ... 3.30

0 280 202029l> 2421a 0.07 ...0.11

0 280 202066 ( - ) ̂ 0.09 ... 0.10

Sensor plate openCode no. (FDle nominal value (V)

FD = date of manufactureTesting tempereture =18 . . .250 C (65 . . .770 Fl

0 280 203 016 ( - ) e 4.01 ... 4.35 0 280 202039 ( - I e 0.03 ... 0.07

o 280 2O2O2g l> 242l-e 4.oo ...4.60

0 280 202 066 ( - ) a 4.21 ...4.57

(

FUEL SYSTEM

13-6

Air Flow SensorWiring Diagram / Connections

BMW Servico TesterM 06 = test value

Air tomperature sensor integratedin air flow mster

Gode llumber Test Temp. Nominal Value(o C) (K'0hms)

Gode Number Test Temp. Nominal Value(o Cl (K-Ohmsl

. r0t 0.5 a 826 ... 10.560 280 203 016 +20 r 0.5 a 228 ...2.72

+50 r0.5 a 0.?6 ...091

- l0 t | ^ Ug x 0.4934 ... 0.52800 280 202 039 +20 t | = Ug x 0.5346 ... 0.5654

+50t1 a U9x0.5599.. .0.5902

- t0 r 0.5 a 826 ... t0.560 280 202 029 +20 t 0.5 e 228 ...2.72

+50 r 0.5 a 0.76 ... 0.gl

. t0 r 0.5 a 826 ... t0.560 280 202 llo0 +20 r 0.5 e 228 ...2.72

+50 r 0.5 a 0.76 ... 0.91

it l \a

FUEL SYSTEM

13 -7

Air Flow SensorWiring Diagram / ConnectionsUniversal Test Adapter

BMW Service TesterM 13 with 500 HeruM 02 test value

I ----- ----.-r

LffiHMO2F

lg ll l l

i_lthl_L;59E78t t t - |rir"r Tsl r_1M o2F

Sensor plate closedCode no. (FDle nominal value (Vl

FD = date of manufactureTesting temperaturo =18 . . .250 C (65 . . .770 Fl

0 280 203 O25 ( - l a 0.29 ... o.3o 0 280 203 027

o 280 202082 0 280 203028

0 280 202091 ( - ) a 0.09 ... 0.10

Sensor plate openCode no. (FDle nominal value (Vl

FD = date of manufactureTesting temperaturs =18.. .25o c (6s . . .77o Fl

0 280 2O3 O25 ( - I e 5.15 ... 5.26 0 280 203027

0 280 203082 0 280 203028

0 280 202091 ( - )a 4.21 ... 4.57

\$ : .

FUEL SYSTEM

13-8

Air Flow SensorWiring Diagram / Gonnections

BMW Service TesterM 06 = test value

t -IIIII

Air temperaturo sensor integratedin air flow sensor

Gods Numbsr Test Temp. Nominal Valus(o Cl (K.0hmsl

Codo ilumher Test Temp.. Nominal Valuo(o cl (K-ohmsl

- l0 t I a Ug x 0.4485 ... 0.48000 280 203 025 +20 t I a Us x 0.4860 ... 0.5140

+50t I a Ug x0.5090.. .0.53650 280 203 027

0280202082 0 280 203 028

t0 r 0.5 a 826 ... 10.560 280 202 091 +20 r 0.5 a 228 ...2.12

+50 r 0.5 e 0.76 ... 0"gl

(/ ):'I t .

\


13 - I from model 1983 on

al 318 i/A al 325 elAb) 325 i/Ac)M3

al528elA a) 533 i/Ab) 535 i/AclM5

a) 633 CS|/Abl635 CS|/AclM6

al733i lAbl735i,lA

13 62... Pressure Sensor

Code no. 0 280 101 001 0 280 110 006: 9.840 280 101 001

0 280 110 006 0 280 110 006cl0 280 101 001

0 280 110 006c)0 280 101 001

0 280 110 006

Resistance between contact (11and (2) in relation to ambientair prersure mbar/ohm

mbar/k-ohm

I 88010 I 88010 a 88010 ' 1 se0l0 1 88010

> 930,bo\ 9.84

\ 930/oo 5 930/e \ 930/oo > 930/oo

t 'qt



al 318 i/A al 325 elAb) 325 i/AclM3

al 528 elA al 533 i/Abl535 i/AclM5

a) 633 CS|/Ab) 635 CS|/AclMG

al733 ilAb) 735 i/Acl 735 i/A-E 32

13 62 ... Coolant Temperature Ssnsor

Code no.Part no.

0 280 130 023.. .1357 414

a, b)0 280 130 023...1 357 414c)0 280 130 026... 1 284 397... 1 709 966

0 280 130 023.. .1357 414

a)0 280 130 023...1 357 414b, cl0 280 130 026...1 284 397... 1 709 966

al0 280 130 023.. .1357 414b, c)0 280 130 026... 1 284 397... 1 709 966

al0 280 130 023.. . .1357 414b, c)0 280 130 026... 1 284 397... 1 709 966

Test values with 4 1 mA testcurrsnt and temperature of

- 10 t 1() c(+ 14 r 20 Fl K-ohms 7.. .11.6 a, bl 7 . . . 11.6c) 8.2 .. . 10.5

7.. . 11.6 a) 7 . . . 11.6b, c) 8.2...10.5

al 7 . . . 11.6b, c) 8.2...10.5

al 7 . . . 11.6b, cl 8.2...10.5

+20 t10 C (68 r2(, F) K-ohms 2.9. . .2.1 a,bl2.1 , , .2.9cl 2.2. . .2.7

2.1 . . .2.9 al2.1 . . .2.9bl2.2 . . .2.7

al 2.1 . . .2.9b, c l 2.2 , . .2.7

+ 80 r 10 C (176 r20 F) K-ohms o.27 . . .0.4 a,bl O.27.,.O.4c) 0.3 . . .0.36

o.27 ... O.4 al O.27 . . .0.4b) 0.3 . . .0.36

al O.27 ... 0.4b) 0.3. . .0.36

al O.27.. .0.4b, cl O.3 ... 0.36

q{ ,L.



al 318 i/A al325elAbl325 ,lAclM3

al 528 elA al 533 i/Ab) 535 i/Ac)M5

a) 633 CS|/Ab)635 CS|/Ac) M6

al733i lAb) 735 i/Acl 735 .lA-E 32

13 63 ... Throttle Switch

Code no. 0 280 120 301 a, b) 0 28O 12O 3O2cl 0 280 120 301

0 280 120 302

Max. permissible opening angle o90

Max. opening angle at partaalload switching point o

1

Max. opening angle at fullload switching point o

66

Resistance at partial load(measured on throttlo switchl k-ohms > 100

Resistance at full load(measured on throttle switch) ohms <3


a) 318 i /A al 528 e/A al 533 i/Ab)535 i /Acl M5

733i,|A1735 i lA| 735 alA-E 32

from model 1983 on

a) 633 CS|/Abl635 CS|/AclM6

al325elAbl325 a/Ac) M3

13 64 ... Electric Fuel Injectors (1)

0 280 150 126...1 273 271.9> 9.840 280 150 714... 1 706 176.9or0 280 150 203.. .1 276149.9c)0 280 150 201...1 273 272.9

o 280 150 201...1 273272.9s 9.840 280 150714... 1 706 176.9oro 280 150 203.. .1276149.9cl0 280 150 201.. .1273272.9

o 280 150 201...1 273 272.9> 9.840 280 150714... 1 706 176.9or0 280 150 203.. .1276149.9

0 280 150 21 1...1 279 665.9> 12.840 280 150 704... 1 706 058.9

0 280 150 126,. .1273271.9\ 9.840 280 150 716... 1 706 414.9c)0 280 150 201...1 273 272.9

0 280 150 126.. .1273271.9\ 9.840 280 150 716... 1 706 414.9

Code no.Part no.

\q

FUEL SYSTEML-Jotronic


13 64 ... Electric Fuel Injectors (21

Code no. D 280 t50 211 0 280 t50 1260 280 150 201 D zso r50;ll 0 280 r50 7t4 0 280 r50 7r6 0 280 t50 704

Spray angle (approx.) o 30 30 30 30 30 30 30

Leak rate in drops per minute I I I I I I I

at tsst prossuro bar (psil 3 (43) 2.5 (301 2.5 {36} 2.5 (36) 2.5 (301 1.5 (361 2.5 (361

Static flow rate cclmin 146 r3 % 161 !3% 236t3% 185 r3 % 189 r3 % ru t3% 170 t?%

at test pressure bar (psi) 3.010.00(43 r 03)

2.5 t0.05(36 r 0.9)

2.5 r 0.05(36 r 03)

3.010.05(43 r 0"9)

3.0 r 0.05(43 r o.el

1.5 r0.05136 r 0.9)

2.5 r0.05(36 t 0.9)

Coil resistance at 20oG (68oF)(approx.) ohms r4.5...(r5.8)

. . .17.52.. .3 2. . .3 r4.5...(t5.8)

... t7.5t4.5...(15.81... r7.5

14.5...{t5.81.. .17.5

t4.5...(t5.81... | 7.5

Color codePlug connection blue light gray dark gray yellow

blueyellow white black

Injector sleeve yellow orangE dark gray yellowyellow

yellow yellow yellow

( ; t -tr

\ l



al 318 i/A al 325 elA al 528 elA a) 533 i/Abl535 i/A

a) 633 CSi/Ab) 635 CS|/A

| 733.1Al735i,lA

13 64 ... Electric Start Valve

Code no. 0 280 170 043 0 280 170 031 0 280 170 032

Flow rate cclmin. 93 !12% 85 !12%

at test pressure bar (psil 3.0 r 0.02(43 r 0.3) ,i

2.5 t 0.05(36 r 0.9)

Leak rate cclmin 0.3

at test pressure bar (psi) 3.0 r 0.02(43 r 0.3)

2.5 r 0.05(36 t 0.91

Spray angle '''l ' approx.80

Coil resistance at4bo c (680 Fl ohms 3 . . .5

. t , '1,t ! , ,

/.:t f.

t

FUEL SYSTEM

13-20

al 524tdA

13 31 . . . FuelSupply

Fuel feed pressure (after filterlat idle speed Uar (psi) 0.3. . .0.6 (4.5 . . .8.51

Transfer pump delivery pressure see Group 16

13 32 ... Fuel Heating

Power consumption of heatingadapter after 5 seconds ofoperation (at 20o C/68o F) 9g.2

Testing voltage V 12.5 t 0.5

Temperature switch (on fuelfilterl

Switching-on temperature(with dropping temp.) oc (orl 5.5 r 2.5 (42 r 5)

Switching-off temperature(with rising temperature) oc (orl - 0.5 t2.5 (31 * 4l

\.(

FUEL SYSTEM

13 51 ... Distributor Injection Pump VP-20

Pump internal pressursat idle speed

Static injection beginning adjust-ment - stroko of distributor piston(with lst cylinder piston at TDCI mm (in.l

Test yalue for static injectionbeginning adjustment - withoutfollowing up with readjustment mm (in.l

Dynamic injection beginning(oi t temp.) 70o c/158o Fl

at idle speed ocrksh. BTDC

at 1500 rpm ocrksh. BTDC

(oil temp.:6bo c / 14oo F)ldle speed

Maximum speed

vE 6/10 F 2400 R 118

3.s. . .4.5 (50.. .641

4.5. . .6.0 (64.. .851

\ 6 (851

0.65 + 0.02 (0.0256 + 0.0008)

0.65... 0.69 (0.0256 ,..0.02721

3.5 t 1.5 (checked with BMWservice test unit and test adapter, engine test P 06)

5.0 r 1.5

750 + 50

5350 t 100

(, {\

FUEL SYSTEM

13-22

al 524 tdA

13 51 ... Electric Shutoff Valve (on Distributor Injection Pumpl

Switchingon voltage V at least 10

Power input W 20

Resistance at 2Oo C {680 Fl ohms 7.5 r 1.0

13 51 ... Timing Valve in Injection Pump

Resistance at 20o C (68(l Fl ohms 10.. .20

1362... Coolant Temperature Sensor (VP-201

Besistance at coolant temperatureof 20o c (68() Fl kohms 2.4. . .3.0

of 8oo c (176() F) k-ohms 0.3 . . .0.5

13 51 ... Control Box for Absolute Pressure Dependent Injection Rate

Absolute regulating pressure ofcontrol box mbar 700 r 15

qt

FUEL SYSTEM

13-23

al 524 tdA

13 53... Fuel Injectors

Nozllo holdor ICodc numbor |KCA3OS52

Fual iniestor ICodc numbor |DNOSD259

OFning prs.u|8 bar (p6il |

15lt + 8 (213 + 114)

Min,oirtion pr€r|||ra b.r (!sil | 135119201

Mrx. orslion prlrturu doviation Iot sll in3t llsd inlocton b.r (otil | 15 12131

Coil r€riianco for injrcior Iwith gjoction timr traDtmittor Isr 2oo c (680 Fl ohm l toorro

I Sholl Crlibration Fluid 8/1487 AWI tholl VS 15 665

13 6l ... Comrol Unit.for lrdoction fump VP.20 (in Glow Box)

t-

\

13-A1 FUEL SYSTEM

Tightening Torque Car or Engine Type Nm (f t . lbs.)

M21

M21

M21

M21

M21

M21

M21

M21

M21

M21

M21

All except M 21

Allexcept M 21

M21

14 !2 (10.5 r 1)

I r 1.5 (6.5 t l l

22 !2 (16 t 1)

14+6(10.5+41

20r5(1414)

15 . . .20 (1r . . . 141

47 t2 (34r 1)

40+5(29+4)

20+5(14+41

20 + 10 (14.5 + 7l

45 (33)

20.. .25 (14.. . 181

12 . . .14 {9 . . . 10}

17 . . . 19 112 . . .14l ,

Fuel lines to filter head{nut/bolt}

Adapter (fuel feedl

M14x1.5

M12x1.5

13 52 . . .

13 53 . . .

Injection pump to holder (front and rear)

Plug for high pressure section ofinjection pump

Electric shutoff to injOction pump

Electric cold start valve

Sprocket to injection pump

Comb. fuel injector to cyl. head

Line to fuel injector (coupling nut)

OUT bolt on injection pump (returnl

Nozzle holder to injection pump(high pressure section)

Temperature time switch

Temperature sensor (coolantl

Temperature sensor (VP-20)

t<\ , \{

10

FUEL TANK AND LINES

Page

Fueltank . . .16-1Fuelpump - lFuel leveltransmitter - 1Fuef inake with transfer pump - 2

E32Page

16-3

-3

\ r

(t

FUEL TANK AND LINES

16 - 1 from 1983 models on

alb)

318 i /A325 elA

a) 524td A a) 528elA alb)

533 i/A535 i/A

albl

633 CS|/A635 CS|/A

alb)

rcs'IA735 alA

16 11 ... Fuel Tank

Tank volume ltr. (gal. l 55 (14.5) 63 (16.61 85{.22.41

Tank cap

16 12 . . . Fuel Pump

without breather

* from models 1986 on

Code number U bUU 4bIT UIJ

0 580 494032r0 580 464Tftt-0580 464032*

Test voltage V 12 t 0,5 12 t 0,5

Power required tor 12Y A 16.5125 * 16.51 15 *

Operating pressure bar (psi) 2,5 .- 3,5 (36 ...43t 2,5 -- 3,5 (36 ...43)

Delivery rate at 12 V ltr. (qts.l/min > 2,2 (2,01

\ 1,9 (> 1,gl *>2,2 l2,ol

\ 1,9 (\1,8) *

16 12 ... Fuel Level Transmitter

ResistanceEmpty tank ohm 71,7 t 2,3 88,2 t 2,5

Ful l tank ohm 3,2 ! O] 4,7 t O,7

I \

FUEL TANK AND LINES


alb)

318 i /A325 elA,

a) 524 td A al 528 e lA a)b)

533 i/A535 i/A

allrl

633 CS|/A635 CS|/A

alb)

rcs'lA735 ilA

16 14 ... Fuel Intake with Transfer Pump

Test voltage

Power required for 13 V

Delivery pressure at+ 200 c (680 Fl

V

A

bar (psi)

12!

< 1.4

0,5

0.3 (4.31

I

FUEL TANK AND LINES '7'Series -E32

I tr. (gal.) 81 / 90* |21.4 I 23.8*l

Via carbon filter to engine exhaust

0 580 464 995

Fusltank volume

Operating pressure bar (psil

Delivery rats at 12 V (pumpremoved - tested with testingfluid) ltr. (pts.)/min.

Delivery rate (pump installedwith counterpressurelSee Gr. 13 in Rep. Manual

Max. power consumption

16 11 . . . FuelTank * Only for cars with ride control

16 14 ... Electric Fuel Pump

ttr

817lo39lOO2817 I O38 /001*

Resistance at connection Gfuel tank empty

fuel tank full ohms

FUEL TANK AND LINES '7'Series - E 32

16 14 ... Fuel Level Transmitter * Only for cars with ride control

T

t

16-A1 FUEL TANK AND LINES


16 11 . . .

16 12 . . .

Fuel tank to body- bolts- nuts

- straps

Connecting pipe on fuel tank

Heat shield to fuel tank

Drain plug on fuel tank

Pump to vibration damper

Holder to fuel pumpffuel reseruoir

Electric connections on fuel pump

E21E30E30E 12,E24E23

E30

830,E23E28,E24

Atl

All with fuel injection



M8M8

20 . . .22 (14.5. . . 16)22.. .24 (16.. . 17)25 . . .28 (18 . . . 20)39 . . .47 (28 . . . 3417 . . .9 (5.5 . . . 6.5)

25 !2 (18 r 1)

8 . . .9 (6.0 . . . 6.s)9 . . . 10 {6.5 . . . 7.0}

21 . . .25 (15 . . . 181

6 . . .7 (4.5 . . . 5.01

6.. .7 (4.5 . . .5.0)

1.s. . .2 (1.0. . . 1.s)

!(,'rt

16 - A 2 FUEL TANK AND LINES

Tightening Torque Type I rum (ft. tbs.l

16 12.. .

16 13.. .

16 14.. .

Plastic nuts on cover for fuel pipes

Fuel pipe to fuel pump

Fuel'pipe to fuet reservoir

Comensation tank to body(for tank Yentingl

Fuel level transmitter to fuel intake

Hose clamps - 10 - 16 mm dia.

E30

Allwith KJetronic

Allwith KJstronic

E28,E24E30,E23

All with fueltransferpump in tankE32

Atl

2 (1.51

20.. .25 (14.5. . . 181

29.. .35 121 . . .251

2.5. . .3.5 (2.0. . .2.514.. .5 (3.0 . . .3.51

1.8. . .2.0 (1.3. . . 1.5)I (61

2.0 t 0.3 (1.5 r 0.2)

tit {

10

17 RADIATOR

Page

Coof ingsystom . . , .17-1Radiator - 1Cool ingsystemcap.. -1Transmission oil cooler - 2Extra fan - 2

E32Page

17 1011

17 -3

-32240

a) 524 td A 528 elA al 633 csi/Ab) 635 CS|/A

17 10... Cooling System

Coolant volume Itr. (qts.l 12112.71

Antifreeze and corriosioninhibitor, mixing ratio andwater properties see Service lnformation of Gr.00

17 11 .,. Radiator (with Transmission Oil Cooler)

Test pressure bar (psi)

17 11 ... Cap for Cooling System

Pressure valve opens at bar (psil

Vacuum valve open until bar (psil

717.4111 (11.61

12 (12,71 11(11,6)

1.5 (211

1,4 t 0,1b) 1,2 t 0,1 1,0 t6 ' i

0.e (131

RADIATOR

17 -1

alb)

318 i /A325 elA

533i/A535 i/A

alb)

73si lA735 ilA

from 1983 models on

RADIATOR


318 i /A325 elA

a) 524 td A 528 elAb) 535 i/A

633 CSi/A635 CS|/A

733:'/A735 i/A

17 11 ... Transmission Oil Cooter (lntegrated in Radiator)

8 (1141

12 (170l-

365 (14.370)

Operating pressure bar (psil

Testing pressure bar {psi)

17 40... Extra Fan (Electr ic)

mm ( in. l

Testing voltage

Power inputSpeed I

Speed ll

Temperature swichtes for extra fan see group 6l

<11 t 10%

<30 t 10%

1400 I 24c,O ! 10 %

RADIATOR '7'Series - E 32

17 10... Cooling System in General

Goolant volume ltr. (qts.) 12 (12.71

Coolant specif ications see Operating Material Specification binder

17 11 ... Cap for Cooling System

2.0 r 0.1 (28 r 1.5)

0.9 (131 absolute

1.0 (141Testing pressure for coolingsystem bar (psi)

17 11 ... Engine oi l Cooler

Oil volume (incl. hosesl Itr. (pts.l 0.75 (1.6)

Pressure valve opens at bar (psil

Vacuum valve open until bar (psi)

17-A1 RADIATOR


Coofant hoses 32 ...48 mm dia.

Radiator to body- self-tapping screws B 6.3- screws M 6

Drain plug on radiator

Temperature switches on radiator(910C/990C}

Compensation tank to body

Engine oil cooler to body

Pipes on engine oil cooler

Holder for oil cooler pipes

Bleeder screw (8 mml on thermostathousing

2 + 0.5 (1.5 + 0.3)

8+1(6.0+0.519+1(6.5+0.51

z 1E:8 tr.s | $.ty

8+1(6.0+0.51

8+1(6.0+0.51

12+2(9+2)

25+5(18+31

5+1(3.5+0.51

6 . . . 10 (4.5. . .7.01

\\

Coupling nut on transmissionoil cooler (on radiator) andon transmission

Oil pipes on transmision- hollow union bolts

Oil pipe on transm. oilcooler- hollow union bolts

q

All with autom. transm.


18+3(13+2)

35+3125+21

25+3{18+2)

35+3125+21

25+5(18+2)

1.7 + 0.5 (1.2 + 0.31

6 . . .7 (4.5 . . .5.0)

17 22.. .

Ml8x1.5

Ml6x1.5

M14x1.5

Adapters on transmissionM14x1.5+M16x1.5

Oil hose on oil pipe

Oil pipe holder to radiator

Oil pipe holder to body


745 iA

745 iA

745 4A

17 - A2 RADIATOR

Tvpe I rum (ft. tbs.l

18-A1 EXHAUST

Tightening Torque

{\

Nm (ft. lbs.l

Exhaust pipe to manifold or turbocharger

To triangular flange

Exhaust carrier to transmissionand exhaust assembly

Rubber mount bracket to exhaust carrier M 6M8

Clamp for final muffler

Clamp on exhaust carrier

Bracket on rear axle carrier

Clamp on final muffler

Exhaust pipe connecting sleeve(after replacing mufflersl

Clamp on catalytic converter

Heat shield to exhaust assembly(B 6.3 self-tapping screw)

M10M 20'3'seriesM 30 - M 20 '5'seriesAtlAtlE32

AilM20M10/M30

Cars with cat. conv.

50.. .55 (36 . . .4016 (4.51 uniformlyagainst block; thenloosened 1.5 turns.

22+2 (16 + 1l

22+2(16+11e.. . 10 (6.5. . .7.0122+2 (16 + 1)max. 16 (11.51max. 14 {10}max. 14 (101

22+2 (16 + 1)24l17l16 (11.5)

22+2{16+1122+2 (16+ 1l22+2(16+1)

7 . . .8 (s.0 . . .6.0)

t f

10a

21 CLUTCH

Specifications

Explanation of engine designationsClutch in general

EngineM10lM20lM30 /S t4ls 38page

. .zt - t-2

21 0021

5152

Clutch discDrive plateClutch release

223Clutch operation

-3

t (,' a\

CLUTCH

from 1983 models on

Explanation of engine designation M 10

Expfanation of engine designation M 20



Explanation of engine designation S 38

Explanation of engine designation S 14 al M3

825al 325i

827al 325,325 e,325 esbl 528 e

832al 533 ib) 633 CSic) 733 i

834al 535 ib) 635 CSic) 735 i

835al 735a-E32

alb)

M5M6

q \

CLUTCH


818 B 25 827 832 834 835

21 0O... Clutch in General

Hydraulic fluid brake fluid (see Service Informationl

21 21 ... Clutoh Diro

t*"

Color codo {paint dot} lbluo I nono I brown

Ddi8tion at tip. ol diaphngm Ilprin$ mm (in.)

| 0.6 (0.0241

21 21 .,. Drivo Plat' t | ,

Typ. | 215 PsD rl | 228 wrD | 240 PsDil

ou$ido diamot r mm (in,l L315

(8.465) I 228 (8.s761 | 2/ro (9.449)I

Min. lincr thicknor. mm (in.l | 7.5 (0.295)

M!x. pErall3l ddirtion betw. Iboth lined surtacor mm (in.l

I 0.15 (0.0061

M6x.l.toral runout mm (in.l | 0.5 (0.020)

*) from 10.83 on 4 step-driveplate

CLUTCH

from 1983 models on

2151 ... Clutch Release

Make

Inside dia. A

Height B

mm ( in. l

Fichtel&Sachs/SKF

38 (1.4e61

Fichtel & Sachs mm ( in.)

mm ( in.)

mm ( in.)

4910.4 (1.929 r0.016)

SKF

Height C

51.5 r 1.O 12.028 r0.039)

25 *.O.25 (0.984 r0.010)

Master cylinderBore dia. mm ( in. l 1e.05 (0.750)

mm ( in.) 32 (1.2601

Slave cylinderBore dia. mm ( in.) 20.64 (0.8121 I 22.2 (0.8741*

21 52... Clutch Controls

+ Only for 733 i

mm ( in.) 23 (0.e05)

l{ka

t-Y

CLUTCH

21 - from 1983 models on

s14M3

s38M5M6

2100.. . Clutch in General

Hydraulic fluid brake fluid (see Service Informationl

21 21 . . . Clutch Disc

Type MF 228 MF 240

Color code (paint dot) green yellow

Deviation at tips of diaphragmsprings mm (in. l 0.6 (0.0241

21 21 . . . Dr ive Plate

Type 228 24OTD

Outside diameter mm (in. l 228 240

Min. l iner thickness mm (in. l 7.5 (0.295)

Max. parallel deviation betw.both lined surfaces mm (in.l 0,15 (0.0061

Max. lateral runout mm (in.) 0.5 (0,0201

*) from 10.83 on 4 step-driveplate

{v(

CLUTCH


s14M3

s38M5M6

2151.. .ClutchRelease

Fichtel& Sachs /SKFMake

Inside dia. A mm (in.)

Height BFichtel & Sachs mm (in.l

mm { in. l

mm ( in. l

SKF

Height C

II

I

t

BIar m

21 52. . . Clutch Controls

Master cylinderBore dia. mm ( in. l

mm ( in.)Stroke

Slave cylinderBore dia. mm (in.l

mm (in.)Stroke 23 t0.e0s)

51.5 t 1

19.05 (0.7501

32 (1.260)

20.64 (0.812)

\fLt,

21 -A1 CLUTCH

Tightening Torque Nm (f t . lbs.)

Clutch housing to crankcase

- Torx bolts

Clutch disc to flywheel- bolts 8.8- bolts 10.9- fillister head bolts 8.8

2152 ...Connectors for hydraulic lines

Master cylinder to console

Master cylinder setscrew

Master cylinder to pedal base

Slave cylinder to clutch housingor transmission case

AtlAtl5,6 and 7 series

Atl

Atl

Arl

Atl

Atl

21 . . .27 (15 . . .20140.. .50 (2e . . .36178 . . .86 {56 . . .62)19 . . .24114 . . .171

22 . . .24 (16 . . . 17)30 ...35 122 ...25122.. .26 (16.. . 191

13.. . 16 {e . . . 121

22.. .24 (16.. . 17)

21 (151

e (6.51

24l17l

tui ' . , i

10a

MANUAL TRANSMISSION

Specifications

Transmission/model surueyTransmission in general . . . .Case and covers

23

Page

23-1-2-3

23 0011212223

31

Shafts - 4Gears - 4Synchronization . - 5Guide slewes - 5I nternal shift components -6

MANUAL TRANSMISSION

from 1983 models on

a) 325b) 325 ec) 325 esd) 325 ie lM3

a) 528 e al 633 CSib) 635 CSicl MG

Transm ission/Model Survey

Type240 - 5-speed overdrive

Type ZF S 5-16 - S-spead overdrive

Type 260 /5 - 5-speed overdriva 1blType 265 /6 - 5-speed overdrive

Type 260/6 - S-speed overdrive c)

Type 280 - 5-speed sport

a) b) c) d)

al 533 ibl 535 i

" ) Mb

a) 733 ibl 735 ic l735iE32

3.\ \ l

MANUAL TRANSMISSION


240Five SpeedOverdrive

zF-ss-16Five SpeedOverdrive



280Five SpeedSport

23 00 ... Transmission in General

Oil grade see Service I nformation

Oilvolume ltr. (pts. l 1.15 (2.4) 1.15 (2.41 1.2s {2.65) 1.6 (3.4) 1.25 (2.651

lst gearRatioNo. of teeth

3.7233x41mTm

3.7235x43m

3.8334x4126Fia'

3.8234x38ffii:t

3.5138x43z6]-m'

2nd gearRatioNo. of teeth

2.O233x35M

2.O435x33m

2.2034 x37m

2.2034 x37m

2.0834x3526 x22

3rd gearRatioNo. of teeth

1.3233x28ffi

1.3435x31Tffi

1.4034x30M

1.4034x31m

1.3534 x2926 x28

{th gear

i , Ratio.' No. of teeth 1'oo 1.00 loo 1.00 loo

Sth gearRatioNo. of teeth

0.8133x26ffi

0.8035 x242

0.8134x26ffi

0.8134 x23ffi

0.8134 x2626 x42

't:r

MANUAL TRANSMISSION

from 1983 models on

zF-s5-r6Five SpeedOverdrive


280Five SpeedSport

23 00 ... Transmission in General

Reverse gearRatioNo. of teeth

2311 ... Case and Covers

Temperature for installationof bearings

3.7134x19x3426x12x19

tY

MANUAL TRANSMISSION






280Five SpeedSport

23 21 ... Transmission Shafts

Axial bearing clearance ofoutput shaft mm (in.) 0.. . 0.0s (0. . . 0.0035)

input shaft mm (in.) 0.. .0.09 (0 . . .0.0035)

Axial play of synchromesh ringon input shaft mm (in.l

1.1 . . . 1.3(0.043...0.05t1

on layshaft mm (in. l 0.13...0.23(0.005...0.009)

0.13...02310.005...0.0091

0.15...020(0.006...0.0081

Orqilt straft jolrrnl rdial rcurult mm (in.l 0.07 (0.00281

Output flangeRadial runout mm (in.) 0.07 (0.0028)

Axial runout mm (in.) 0.1 (0.0039)

23 22 ... cosn (Lry3haft)

Prer.ing ott folcs.nd tomporaturs | | | | |3rd sorr ronr | - | z.s | - | s...2 |oc (oF) | lon.2o0o) | l .nn.zrioor I4rh0ear ronr | - | -9.9_-. | - | Er..l_-. Ioc to r) | | +p.zo tzo) | | uo.id izor Isrh scsr tonr | 4.5... s.5 | g.o I s.s... e.s I s -.- ro Ioc(oF) l.pn,120 (2501 | u!.20 t70l I p!.t2[o50t lrDtr.irt; l I

MANUAL TRANSMISSION

23-5 from 1983 models on





280Five SpeedSport

23 22... Gears ( Layshaft)

Pressing on force and temperaturs3rd gear tons

oc (oF)

tonsoc (oF)

4th gear

sth gear tonsoc (or)

23 23 ... Synchronization

D istance between synchromeshring and clutch body

New condition mm ( in. l

mm ( in.)Max. wear l imit

Reverse gearNew condition mm ( in. l

mm ( in. lMax. wear l imit

0.015150 . . . 180(300.. .3501

5.0. . .5.5approx. 180(350)

0.015150 ... 180(300.. .3501

5.0. . .5.5approx. 180(350)

4.9 . . .6.8approx. 120(2501

5.0. . .6.0approx. 180(3501

4.0. . .5.5approx. 120{2501

0.015150 ... 180(300.. .350)

1.0. . . 1.3 (0.039 . . . 0.051)

0.8 (0.031)

0.5 .. . 0.6 {0.020... 0.024)

0.4 (0.016)

1.0. . . 1.3(0.039...0.0511

lst/2nd gears:0.7 (0.028)

0.9 (0.03s)

0.8 (0.031)

0.5 . . .0.6(0.024 ...0.024)

{ti\ l

MANUAL TRANSMISSION

23:6 from 1983 models on





280Five SpeedSport

23 23... Guide Sleeves

Pressing off forcelsV2nd/5th/reversegears tons max.3.0 max.0.08 max.3.7

3rd/4th gears tons max.2.7 max.0.08 max.3.0

Pressing on forcelst/2ndlSth/reversegears tons max.2.1 max.0.08 max.2.5

3rd/4th gear tons max. 1.9 max.0.08 max.2.1

23 31 ... lnterior Shift Parts

Selector fork guide width1st. . .4th gears

Wear l imit mm (in. l 4.8 (0.18e) 4.8 (0.18e)

23- A 1 MANUALTRANSMISSION

Tightening Torque Nm (ft. tbs.l

Transmission to engine- hexagon head bolts

Transmission to clutch housing

Reinforcement plate to transmission

Oil drain plug/oil filler plug

AtlAilArl

AtlAllAtl

AI

Atl

Atl

22. . .27 (16 . . .20)47 . . .51 lA . . .37166 ...82 (48 ... 591

20 . . ,24 114 . . .17138 ...47 127 ...34164 . . .80 (46 . . .58)

72 . . .80 (52 . . . 581

22.. .24 (16.. . 17)

40 . . .60 (29 . . .43)

t " 'ta \.

2311 . . .Transmission case covor totransmission case

Cover with guide tube totransmission case

25 (181

18 (13)25 (18110 (71

10.5 {81

4e (35)

25 (181

25 (18140 ... 50 (29 ...36)

25 (18)

10 (71

10 (71

60 (431

Bearing cover to sealing flange

Revene gear shaft to intermediate case

Reverse gear shaft holder to intermediateGase

Reverse gear shaft to case

Support for rwerse gear shaft

Bearing holder to rear cass section

Sealing cover mounting tabs

Bearing to layshaft(with bolt cementl

M8x22M8x30M6

M8M10

M8

M6

M6

M10

23 - A2 MANUAL TRANSMISSION

Tightening Torque Type | rur (ft. tbs.l

AllAtlAtl

Atl

Atl

Ail

AtlAtl

2401260

240126012651280

280

280

\(,I

23-A3 MANUALTRANSMISSION


Plug for rear case section

End cover on rear case section

Pivot bolt on pivot lever

Clamps on resr case section

Cylinder head bolts

Bolts on lockplate

23 21 ...Output flange

Atl2402601280

24012601280

zF s-5/16

zF s-5/16

Atl

zF s-5/16

60 (43140 (2el60 (431

10 (71

40 ...45 (29 ... 331

30 ...35 122 ...25l-

25 (181

8.. . 10 (6.0 . . .7.01

100 (721with Loctite No.270or Hylogrip

(i

II

4i ,\

Transmission rubber mount tocross member

Transmission

Gros member to body

Bracket to transmission

M10

M10

M8

M8

43 . . .48 {31 . . .35)

43 . . .48 (31 . . .35)

22.. .24116.. . 171

22.. .24 (16.. . 171

':' \

23 - A,4 MANUAL TRANSMISSION

Tightening Torque Type I rurn (ft. tbs.l

, l t \ , t

tq

11

AUTOMATIC T RANSMISSION

I

3040

ZF 3.HP.22:Transmissioningeneral . . . . 24-Upshift pointsDownshift pointsMainpressure. . .Valve body .Torque converter

ZF 4-HP-22lHzModels 318 aA.325 eA, 325 iA,524 tdA, 528 eATransmission in general . . . 24 -Shift points

Page

24-16-17-19

123445

67III0

Oil pressureInput shaft21

3040

Valve body .Torque converter - 1

ZF 4-HP-22lHzModels 533 iA,535 iA,633 CS|A,635 CS|A,733 iA,735 iATransmissioningeneral . . . . 24-11Shif tpoints . . . -12Oil pressure - 14Input shaft - 14Valvebody. -14Torque converter - 15

24 00

213040

ZF 4.HP.22IEH:Models 535 4A,635 CS|A,735 iATransmission in general . . .Shift pointsOil pressure

214061

Input shaft - 19Torque converter - 20

-20,. '

t "

I

AUTOMATIC TRANSMISSION

zF-3-HP-22

24-1 from model 1983 on

a) 318 i

b l 318 iA

al 533 i

bl 533 iA

al 733 i

bl 733 iA

al 528 e

b) 528 eA

al 633 CSi

bl 633 CS|A

24 OO ... Transmission in General

Designation

Transmission no.

Code letters on data plate

Ratios 1st gear

2nd gear

3rd gear

Reverse

Oi lgrade

Total oil volume for new orexchange transmission(transmission and oil cooler) Itr. (pts.l

Initial oil volume for new orexchange transmission withdeep oil sump Itr. (pts.l

Itr. (pts.)Oil change volume (transmis-sion at operating temp.)

see Service Information

5.7 . . .6.112.O ...12.91

6.85.. .7.25(14.5. . . 15.31

2.214.61

2,O 14.21

(\

AUTOMATIC TRANSM ISSIONzF -3 -HP -22

24 -2 from model 1983 on

a) 318 i

b) 318 iA

al 528 e

bl 528 eA

al 533 i

b) 533 iA

a) 633 CSi

bl 633 CSiA

al 733 i

bl 733 iA

240O... Upshift Points

Selector lever position Dlst/2nd gearFull throttle accelerator pedal positionShift point at engine speed rpm

38904650

29903550

38704660

road speed km/h (mph) 43l27l52l32l

43l27l53 (331

54 (34166 (411

Selector lever position Dlst/2nd gearKickdown accelerator pedal positionShift point at engine speed rpm

road speed km/h (mphl

54506300

42904810

54806130

62 (38172 (451

66 {41)75 (461

71 (44!82 (511

Selector lever position D2ndl3rd gearFull throttle accelerator pedal positionShift point at engine speed rpm

road speed km/h (mph)

49405440

39704810

49905440

e8 (61)108 (67)

102 (63)112l70l

118 (731130 (811

Selector lever position D2ndl3rd gearKickdown accelerator pedal positionShift point at engane speed rpm

55806040

[490t820

55906030

road speed km/h {mph) 11 1 (691121 (751

116l72l125 (78)

127139

(7el(861

al 528 e

bl 528 eA

al 633 CSi

bl 633 CSaA

Selector lever position D3rd to 2nd gearFull throttle accelerator pedal positionShift point at engine speed rpm


Selector lever position D(3rd to 2nd gearlKickdown accelerator pedal positionShift point at engine speed rpm

road speed km/h {mphl

Selector lever position D(2nd to lst gear)Kickdown accelerator pedal positionShift point at engine speed rpm


76 (47l-87 (54)

79 (4el8e (55)

e3 {58}105 (65)

106 {66)116l72l

110 (681120l75l

134 (83)145 (eol

s7 (3s)67 (411

77 l48l88 (55)

\


a) 318 i

b l 318 iA

al 533 i

b) 533 aA

al 733 i

bl 733 iA

24 -3 from model 1983 on

.{.\Y:



a) 318 i

b) 318 iA

al 528 e

bl 528 eA

al 533 i

bl 533 iA

al 633 CSi

bl 633 CS|A

al 733 i

b) 733 iA

24 00... Downshift Points

Manual downshift from D to 2(3rd to 2nd gear)Shift point at engine speed rpm

road speed km/h (mphl

33003800

28303150

36004050

112 (7Ol124l77l

116l72l128 (801

135 {841148 (ezl

Manual downshift from 2 to 1(2nd to lst gearlShift point at engine speed rpm 2700

335021702640

29003500

road speed km/h (mphl 61 (38)72l45l

61 (38)73 (45)

75l47l88 (55)

24 0O ... Main Pressure

Main pressure with selectorlever at"R" Neutral bar (psi) 1 2.5...1 4.5 11 7 8...2061 12.5 . . .14.5 (178 . . . 2061

Kickdown Uar (psil 1 6.5... 1 8.3 1234-.2601

"1,2, D, N, P" Neutral Uar (psi l 5.5...6.4 (78...91) 5.5 . . . 6.4 {78 . . . 91)

Kickdown bar (psil 7.2. . .8.O (102.. .113) 7.6 . . .8.5 (108 . . . 1211

24 30 ... Valve Body

Distance between valve bodyand needle on throttle piston mm (in.l 11.5 (0.453) 11.5 (0.4531

AUTOMATIC TBANSMISSIONzF -3 -HP -22

from model 1983 on

al 533 i

b) 533 iA

al 733 i

bl 733 iA

al 528 e

bl 528 eA

al 633 CSi

bl 633 CS|A

24 40... Torque &nverter

Code

Stall speed

Journal dia.

rpm

mm ( in. l 32 (1.260132 (1.260l

a) 318 i

b) 318 iA

\

AUTOMAT!C TRANSMISSIONZF4 HP_22 I H


318 iA 325 eA 325 iA 524 tdA 528 eA

24 00... Transmission in General

Designation

,Transmission number

II

Code letters on data plate I

2ndgear I3rd gear I4th gear IReverse I

Oil srade I

and torque converter empty) ltr. (pts.) |

Init ial f i l l ing volume for new Iand exchange transmissions ltr. (pts.)

|Oil change volume I(at operating temperaturel ltr. (pts.)

|

zF-4HP-221H

AUTOMATIC TRANSM ISSIONZF4 HP_22 I H

24 -7 from 1983 models on

318 iA 325 iA 524 tdA

Selector lever in DAccel. pedal at partial throttleShift at engine speed (rpm)

1-22-33-4CL closedCL open

Shift at road speed (km/h) 1-22-33-4CL closedCL open

Selector lever in DAccel. pedal in full throttleShift at engine speed (rpm)

1-22-33-44-3*3-22-1

Shift at road speed (km/h) 1-22-33-44-33-22-1

* CL closed prior to shift

7' l ' r ,

2190...22102130 ...24002150...22802630...27302100 ...2240

2130...21502070'...21752080 . . .21602190...22301430.. . 1540

2300...23202370...25602360.. .24602510.. .25901880 . . .2020

2490...2510246.0...24702460...24802470...24901530.. . 1630

2170 ...21902110.. .22102110 ...21902250 . . .23101480.. . 1600

17 . . .1833 . . .4148 . . .5580.. .8677 . . .83

14.. . 1522.. .3137 . . .4479.. .8476 ... 81

21 . . .2230 . . .3845.. .5479 . . .8576.. .82

22.. .2334.. .3s52 . . .5878:. . 8375.. .80

21 . . .2231 . . .3846 . . .5583 . . .9080 . . .87

4130 ...49704980 ...54504440 ...47802480 ...27402690...29402220...2650

4570...53204980 ...54304600.. .49602600 ...28702830 ...3oOO2540...2s40

3300 ...39704020...44003760 ...40602090 ...23002390...25202120...2360

3370.. .39503920 ...42503650 . . .38802030...22202570...26602500.. .2550

3320.. .39804030 ...44003770 ...40602090 . . .23102430...25702170 ...2390

48.. . 60100.. . 111138.. . 1s0112 . . .12371 ... 8231 ... 46

37 ... 4680 ... 89

110.. . 12090 ... 9958.. . 6723.. . 36

52... 6297.. . 106

131 . . .142107 . . . 11870.. . 8038 ... 51

40.. . 4985.. . 93

121 . . . 130100.. . 11061 . . . 7034 ... 38

49.. . 60102.. . 113 i r140.. . 153114 . . .12672.. . 8431 ... 47

I.!...I

AUTOMATIC TRANSMISSIONZF4 HP_22 I H

24 - I from 1983 models on

318 iA 325 eA 325 iA 524 tdA 528 eA

24 0O... Shift Points

Sefector lever in D 1-2Accel. pedal at kickdown 2-3Shift at engine speed (rpm) 3-4

4-33-22-1

5350 ...60905480 ...5930

lmmeoiatety3510 . . .38002820...3280

4230 ...48204430.. .4 00

immediately3000.. .3230zMO ...2700

5300 ...56005470 ... 59206020 ...60904110 . . . 41603650 ...39702900 ...3340

4200 ...47804280 ...4620

immediately2980 . . . 31102600...2840

4230...48204430 ...4800

immediately2980 ...32502480...2740

Shift at road speed (km/hl 1-22-33-44-33-22-1

50 . . .5789 . . .97

immediately84 . . .9340 . . .50

63.. . 73111 . . . 121

immediately104 . . . 11550.. . 63

62... 70107.. . 116175 . . .177169 . . . 171r100.. . 11150.. . 61

52... 6094.. . 102

immediately88.. . 9742... 52

64.. . 74112 . . .124

immediately106.. . 11851 ... 64

Manual shift at enginespeed (rpm)

4-33-22-1

immediately3410 . . .38102420...2990

immediately2880 ...32301950 ...zMO

immediately3290 ...37002530 ...3050

immediately2290.,26002110 ...25AO

immediately2890 ...32301960.. .2450

Manual shift at road speed 4-3(km/h) 3-2

2-1

immediately93.. . 10444.. . 53

immediately116 . . . 12956.. . 68

immediately103.. . 11455 ... 65

immediately90.. . 10153.. . 63

immediately118.. . 13257 ... 69

Reverse gear locked atroad speed km/h 18 . . . 19 25.. .27 21 . . .23 28 . . .30 25 . . .27

* GL closed prior to shaft

AUTOMATIC TRANSMISSIONZF4 HP-22 I H

from 1983 models on

318 iA 524 tdA

Pump pressure with selector in D1st gear Neutral bar (psi)

Kickdown Uar (psil

at engine speed rpm

2nd-4th gears Neutral Uar {psi}Kickdown bar (psil

Reverse Neutral bar (psi)

Kickdown bar (psi)

Gonverter pressure withselector lever in D- convorter lockup closed - bar (psil

24 21 ... Input Shaft

Axial play of input shaft

24 30 ... Valve Body

o.2 ...0.4 {0.008 ... 0.0161

Distance adjusted between valvebody and needle on piston 1 1.5 (0.453)

9.1 . . . 10.11129 ...1441

6.0 . . .7.5 (85 . . . 107)9.9. . . 11.0 (141 . . . 1561

approx.4000

7.2. . .8.O(102.. . 1141

4.6 . . .5.8 (65.. .82)

7.7 . . .8.7 (110.. .1241

14.8 . . . 16.7|.211 ...2381

11.0. . . 13.0 (156.. . 185116.1 ... 18.2 1229... 259)

0.7 (10)

AUTOMATIC TRANSMISSIONZF4 HP_22 I H


524 tdA

24 40... Torque Converter

260 (10.2361Converter diameter

Stall speed

Journal diameter

mm ( in. l

mm ( in.)

AUTOMATIC TRANSMISSI ONzF-4 HP-22 | H


533 iA 633 CS|A

24 O0... Transmission in General

Designation

Transmission number

Code letters on data plate

Ratios lst gear

2nd gear

3rd gear

4th gear

Reverse

Oi lgrade

Total o i lvolume(transmission and torqueconverter emptyl Itr. (pts.l approx.7.5 (15.81

Init ial f i l l ing volume for newand exchange transmissions ltr. {pts.}

Oil change volume(at operating temperaturel ltr. (pts.l

zF-4HP-221H

1043 010 126 1043 0t0 1261043 010 097

1 043 010 270 043 010 263 1 043 010264

approx. 2.214.61

approx. 3.0 (6.3)

\r' ,:lfTq

AUTOMATIC TRANSMISSIONzF-4 HP-22 / H

24 - 12 from 1983 models.on

533 aA 535 iA 633 CS|A 635 CS|A 733 iA 735 iA

24 O0... Shift Points

Sefector lever in D 1-2Accel. podal at partial throttle 2-3Shift at engine speed (rpm) 3-4

CL closedCL open

2210...22302300...24902300.. .23902360.. .24301688 ... 1839

2196...22132258...24392252...23512341 ...24061678 . . . 1816

2210 ...22302300...24902300 . . .23902360.. .24301688 ... 1839

2196...22132258...24392252...23512341 ...24061678.. . 1816

2210...22302300...24902300.. .23902360.. .24301688.. . 1839

,.2213..2439..2351

2316.. .23831623 ... 1768

219622582252

Shift at road speed (km/h) 1-22-33-4CL closedCL open

20.1 ...20.730.9 .. .48.856.9 . . .65.083.9 . . .91.480.8 . . .88.3

19.8 . . .20.436.9 .. .46.454.1 . . .61.484.1 . . .90.781.1 . . . 87.8

20.5. . .21.239.7 .. .49.958.2 . . .66.587.6 . . .95.184.5 .. .92.0

18.9. . . 19.535.2 ... M.351.6 . . .59.180.2 ... 86.677.4 .. .83.8

20.5. . .21.239.7 .. .49.958.2 .. .66.587.6 . . .95.184.5 .. .92.0

19.4 . . .20.036.1 . . .45.452.9 .. .60.579.6 . . .86.576.8 . . .83.6

Sefector lever in D 1-2Accel. pedal at full throttle 2-3Shift at engine speed {rpm} 3-4

4-33-22-1

4140 ...47904960 ...53404580 . . .48802574...28012760...29602380 . . .2650

4062 ...47674826.. .52564460 ...48062504...27592708...29092337 ...2645

414O ;..47904960 ...53404580 ...48802574...28012760...29602380.. .2650

4062 ...47674826 ...5256

'1460 ...48062504...27592708...290s2337 ...2645

4140 ...47904960.. .53404580.. .48802574 ...28012760.. .29602380.. .2650

4062 ...47674826 ... 52564460... 48062604...27592708...29092337 ...2645

Shift at road speed (km/h) 1-z2-33-44-33-22-1

56.1 ... 65.6114.1 . . . 123.6154.9. . . 165.9126.4 .. .137.483.0 .. . 93.537.4 . . . 51.6

54.3... 64.6109.7 .. . 120.3149.0. . . 161.5121.O.. . 133.379.0. . . 90.534.9 ... 50.5

57.4 .. . 67.1116.7 .. . 126.4158.4. . . 169.7128.8 .. .140.284.2. . . 95.136.8. . . 51.8

51.8. . . 61.6104.7. . . 119.8142.2. . . 154.1115.4 . . .127.275.4. . . 86.333.3. . . 48.2

57.4 .. . 67.1116.7 . . .126.4158.4. . . 169.7128.8 . . .140.284.2. . . 95.136.8. . . 51.8

53.1 ... 63.2107.3 . . .117.7145.8. . . 158.0118.6 . . . 130.577.3 .. . 88.534.1 .. . 49.4

l ' : .

(

AUTOMATIC TRANSMISSIONzF-4 HP-22 | H

- 13 from 1983 models on

533 iA 535 iA csiA csiA 733 iA 735 iA


Sefector lever in D 1-2Accel. pedal at kickdown 2-3Shift at engine speed (rpm) 3-4

4-33-22-1

5430 ...59705570 ...5930

immediately3690 ...39402920...3290

5127 ...57565305 . . .5717

immediately3518 . . .38232801 ...3174

5430.. .59705570 ...5930

immediately3690.. .39402920...3290

5240 ...57505380.. .5710

immediately3590 ...38302910...3220

5430.. .59705570.. .5930

irrJi.trty3690... 39402920...3290

5127 ...57565305.. . 5717

immediately3518 . . .38232801 ...3174

Shift at road speed (km/hl 1-22-33-44-33-22-1

75.1 ... 83.2129.4 .. .138.2

immediately122.1 . . .131.962.4... 72.6

66.5. . . 75.4115.6. . . 125.5

immediately108.3 . . .119.253.3. . . 64.9

76.9. . . 85.1132.4 .. .141.4

immediately124.5... 134.562.9 .. . 73.6

78.2. . . 86.6134.7... 143.9

immediately126.5 .. . 136.763.6. . . 74.6

76.9. . . 85.1132.4 .. .141.4

immediately124.5... 134.562.9... 73.6

68.2. . . 77.3118.5 .. . 128.7

immediately11 1.0 .. . 122.254.7 ... 66.6

Manual shift at rpm 4-33-22-1

immediately3620 ...40302570...3040

immediately3488 ...38762446...2961

immediately3620 ...40302570 ...3090

immediately3510.. .39002460...2970

immediately3620.. .40302570.. .3090

immediately3488.. .38762446 ...2961

Manual shift at road(km/h)

speed 4-33-22-1

immediately132.7... 146.865.2. . . 77.2

immediately120.7 ...133.559.2... 70.2

immediately135.7. . . 150.166.6 ... 79.0

immediately138.8 ... 152.967.8 ... 80.6

immediately135.7. . . 150.166.6. . . 79.0

immediately123.7... 136.960.7. . . 72.0

Reverse gear lockRoad speed (km/hl 25.2 . . .27.1 23.7 ...25.5 25.8. . .27.7 27.2. . .29.2 25.8. . .27.7 24.3. . .26.2

{

AUTOMATIC TRANSMISSIONzF-4HP-22 | H


533 iA 535 4A 633 CS|A 635 CSiA 733 iA 735 iA

24 OO... Oil Pressure

Pump pressure with selector in Dlst gear Neutral bar (psi)

Kickdown bar (psil

6.0. . .7.5 (85 . . . 1071

10.1 . . . 11.2(144.. . 1591

10.5 ... 12.0(14e.. . 171)

10.1 . . . 11.2(144.. . 15e) 9.9. . . 11.0(141 . . . 1561

10.5. . . 12.0(14e.. . 1711

Engine speed rpm approx.4000

2nd to 4th gears Neutral bar (psi)

Kickdown bar (psi)

4.6. . .5.8 (65 . . .82)

8.0. . .8.91114 ...1271

8.1 . . .9.2(115.. . 1311

8.0 ... 8.9 (114 ... 1271 7.7 . . .8.7(110.. . 1241

8.1 . . .9.2(115.. . 1311

Reverse Neutral bar (psi)

Kickdown bar {psi}

11.0 . . . 13.0 (156 . . . 185)

16.7 .. .18.7(238 ...266)

17.2 . . .19.21245...2731

16.7 . . . 18.7 (238 . . .2661 16.1 . . . 18.21229 ...25e1

17.2 . . .19.21245...2731

Converter pressure withselector lever in D-converter lockup closed- bar (psil 0.7 (10!

24 21 . . . Input Shaft

Axial play of input shaft mm (in.l o.2 . . .0.4 (0.008 . . .0.016)

24 30... Valve Body

Distance adiusted between valvebody and needle on piston mm (in.) 11.5 (0.4531

AUTOMATIC TRANSM ISSIONzF-4 HP-22 / H



Converter diameter mm (in. l

Code

Stall speed rpm

Journaldiameter mm (in.)

260 (10.2361

/q

AUTOMATIC TRANSMISSIONZF_4HP_22IEH

24 16 from 1983 models on

325 iA 535 iA 635 CSIA 735 iA 735iA -E32

24 00... Transmission in General

Code ZF_4HP_22IEH

Transmission number 1043 010 513 1043 010 288 1043 010 371

Code on data plate AP XM YM

Ratio lst gear2nd gear3rd gear4th gear

qr. Reverse w2.481.481.000.732.Og

Oil grade * see Service Information

Total oil volume (transmissionand converter drained) 111. (pts.) approx.7.5 (15.85)

Init ial oi l volume for new orexchange transmission ltr. (pts.) approx. 2.214.651

Oil change volume(transmission at operating tg,temperature) /f t l tr .(pts.)

",tt.,;f ,.,,r 1..;r.,

: . 'litit: approx.3.0 (6.341

"* '^

AUTOMATIC TRANSMISSIONZF-4HP-22IEH

from 1983 models on

635 CS|A 735 iA -'E 32

1-22-334CL closed 4CL open 4CL closed 3CL open 3

Program ESelector lever in DAccel. pedal in partial throttleShift at engine speed (rpm)

Shift at road speed (km/h) 1-22-334CL closed 4CL open 4CL closed 3CL open 3

Program E 1-2Selector lever in D 2-3Accel. pedal in full throttle 3-4**Shift at engine speed (rpm) 4-3**

3-2**2-1

Shift at road speed (km/hl 1-22-334**4-3**3-2**

: 2-1

1*t Clutch lbckup closed before shifting.

1980 . . .21802000...21702140...22502290...24001810 . . . 1960

1920...21401980...21202090...22202040...21101480.. . 16302830 ...30201850 . . .2050

1920...21401980...21202090...22202040...21101480.. . 16302830.. .30201850 ...2050

2050...22002100....22002190...22702210...22701670.. . 18204240 ...44303400 ...4200

16 , . .2230 . . .3752 . . .5883 . . .8975 . . .80

18.. .25.34 . . .4159.. .6676 . . .8369 . . .7590 . . .9762 . . .69

19 . . .2636 . . .4362 . . .6980 . . .8772.. .7995 ... 10265.. .72

18.. . 2433.. . 4057.. . 6481 ... 8875.. . 81

135 . . .142130.. . 137

2120 ...45904340 ...46204830 ...50302820 ,..29602750., .28702420...2510

4110 . . .45904340 ...46304410 . . .46102490..,26302200...24002360 ...2500

4110 . . .45904340 ...46304410 . . .46102490 ...26302200...24002360 ...2500

4660.. .51404810.. .50904510 . . .47102610.. .27502650 ...27602370...2470

47 . , .5383 . . .89

144.. . 150116 . . .12266.. .7230 . . .36

55 . . .62 | S2 . . . 5998 ... 105 | 93 ... 100

148 . , . 155 | r 40 . . .147121 . . .128 I 114 . . .12178 . . .85 | t4 . . . 8036 . . .43 | 34 . . .41

58 . . .65101 . . . 107147.. . 153117 . . .12372.. .7833.. .40

AUTOMATIC TRANSM ISSI ONZF _ 4 HP -22I EH


325 iA 535 iA 635 CSIA 735 iA 735iA-E32


Program E 1-2Selector lever in D 2-gAccel| pedal in kickdown 34*rShift at engine speed (rpm) 4-3*i

3-2i*2-1

s00.. .59105630 ...59206200 ...64004300 ...44503490 ...36902920 . . .3150

5430 .;158905630 ...59006440...66404370 ...45203190 . . .33902890.. .3110

5430.. .58905630.. .59006440 ...66404370...45203190.. .33902890 . . .3110

5400.. .59005630 . . .59106200 ...64004330 ...44803470 ...36702840 ...3100

Shift at road speed (km/h) 1-22-33-4rr4-3+r

' 3-2**2-1

63 . . .69110.. . 116186 . . . 192177 . . .18396 . . .10251 . . .57

74.. .81130 ... 137223...230213 ...220113.. . 12060.. .67

71 . . .77123.. . 130211 ---218201 ...208107 . . .11459 . . .83

69 . . .75 '120.. .126202...209194 . . .200104 . . . 111,,55 . . .62

Manual Shifts:At engine speed (rpm) 4-3**

3-22-1

4330.. .44802980 . . .31802390 ...2640

4500 ...46403400 . . .36102730 ...3050

4500 ...46403400 . . .36102730.. .3050

4330 ... rt4803180 . . .33902220...2520

At road speed (km/h) 4-3**3-22-1

178g450

. . 184

.. 100

..57

223...230124 ...13169 . . .76

211 . . .218118 . . .12465.. .72

194 . . .200107 . . .11452 . . .58

** Clutch lockup closed before shifting.

AUTOMATIC TRANSM ISSIONZF - 4HP _221 EH

from 1983 models on

635 CS|A 735 aA - E32

24 O0... Oil Pressure

Pump pressure with selector lever in Dlst gear

No acceleration bar (psil

bar {psilKickdown

Engine speed rpm

bar (psil

uar (psi)

2nd - 4th gearsNo acceleration

Kickdown

Reverse gearNo acceleration

Kickdown

bar (psil

bar (psi)

61 (psilConverter pressure with selectorlever in D (CL closedl

24 21 ... Input Shaft

Axial play of input shaft mm (in.)

5.5. . .7.5178.. . 1071

10.5. . . 12.5 (149 . . . 1781

4.6 ...6.0 (65 ....851

8.1 . . . 10.1 (115.. . 1441

19.4 ... 22.4 1276... 3191

max.0.7 (10)

o.2 ... 0.4 (0.008 ... 0.0161

AUTOMATIC TRANSM ISSI ONZF_4HP_22IEH

24 - 20 from 1gB3 models on

635 CSiA 735iA-E32


260 (10.2361

0 260 002 014 0 260 002007 0 260 002 016

Converter diameter

Stall speed

Journal diameter

24 61 ... AEGS Control Unit

Bosch No.

mm ( in. l

24 - A 1 AUTOMATIC TRANSMISSION


AtlAilAtl

AtlAlt

At l

Atl

Atl

Atl4HP22

Atl4HP224HP22

Atl4HP22

Atl

24 OO ... Transmission to engineHex. head bolts

Torx bolts

Reinforcement plate to transm.

2411 ... Transmission extension

Cover

Converter bell housing

Plug for intermediate plate

M8M10M12

M8M12

M8

M8

M 6x16

M8M10

M10M14M20

M6

M10

24l17l45 (33178 . . . 86 (56 . . .621

21 (15163 (46)

22 . . .24 (16 . . . 17)

23.. .26 (17.. . le l

I ... e (6.0 ... 6.5)

23 . . .26 (17 . . . 1el46 (33)

15.. . 17 (11 . . . 12140 (2e)s0 (361

I . . . e (6.0 . . .6.5)6 . . .7 (4.5 . . . s.0l

15 . . . 17 (11 . . . 12)

3HP224HP 22

Atl

100 . . . 115172.. .831e8 (711

40 ...46 (2e ...33)

10.. . 11 (7 . . .81

10.. . 11 (7 . . .817 . . .8 (5 . . . 6 l

5 (41

2412...

2421 ...

2423.. .

Speedometer bushing

Output flange collar nut

Torx bolts for clutch F ontransmision cass

Valve body to transmision

Valve housing to valve body

M18

M6

M6

3HP224HP22

Atl

M6M6

M6

24 - A2 AUTOMATIC TRANSMISSION

Tightening Torque Tvpe I Nm (ft. tbs.l

2431 ...Oil pump 10 , . . 11 (7 . . .8)

I

24-A3 AUTOMATIC TR ANSM ISSION

Tightening Torque Nm (ft. rtrs.l

Governor flange to transmission

Stud on centrifugal governor

Hexagon nut on stud

Boft on centrifugal govarnor

Governor housing to hub

Pressure regulator to yalve housing M 6

Solenoid to valve housing M 6

Transmission socket to case

Torque convsrter

Transmission lever to transmission M I

Atl

Ail

Ail

Atl

4 HP 22IH

4 HP 22IEH

4 HP 22IEH

4 HP 22IEH

15 . . .17 (11 . . .121

3 ... 3.5 12.2 ...2.51

e . . . 10 (6.5 . . .7.01

10.. . 11 (7. . .81

10.. . 11 (7. . .81

5 (41

5 (41

12lsl

25 . . .27 (18 . . .20147 . . .51(34 . . .371

8 . . . 10 (6.0 . . .7.0)

6t ' (" {

\

Transmision rubber mount tocross member

- transmission

Gross member to body

' | i | ...48 (31 ...351

43 ...48 131 ...351

22.. .24 (16.. . 171

24 * A4 AUTOMATIC TRANSMISSION

Tightening Torque Tvpe | rur (ft. tbs.l

l -i .

t\

PROPELLER SHAFT

'7'Series - E 23

26-4

4 Speed Manual Transmission 5 Speed Manual Transmission Automatic Transmission

2611 ... Propeller Shaft

Deflection torque of universaljoints Ncm (in. lbs.l 20 . . .70 (1.7 . . . 6.01

Preload of center mount inforward direction mm (in.l 4.. .6 (0.157 . . .0.2361

Deflection anglesJoint discs - 32' ... + 28' - 29' ... + 31',

Universal joint, center - 30' ... + 30' - 27' ... + 33',

Universal joint, rear -24' ... + 40' -20' . . . +40'

Deflection Angle

/ poshiv (+)

->A-{-

\

/ nesativ (-l

! - - - -A-,-t-t'

\

PROPELLER SHAFT

'7'Series - 8 32

26-5

5 Speed Manual Transmission Automatic Transmision

2611 ... Propeller Shaft

20.. .70 (1.7. . .6.0)Deflection torque of universaljoints Nqm (in. lbs.l

Preload of center mount inforward direction mm {in.}

Deflection anglesJoint discs

Universal ioint, center

-Universal joint, rear

Deflection Angle

I positiv (+)

/ nesativ (-)

->rA- J----A-

\-r-v--- <=rz-

4 . . .6 (0.157 . . .0.2361

- 23', ... + 37', -21' . . . + 39'

26_A1 PROPELLERSHAFT

Tightening Torque Nm (ft. tbs.)

2611 ... Propeller Shaft Assembly

Joint disc to propeller shaft andtransmission M10-8.8

M 10 - 10.9M12M12

Propeller shaft universal jointto transmission M 10

Clamping ring for slide afterinstallation in car

Propeller shaft to drive flange(rear axlel

Universal joint

Constant velocity joint

Pivot to propeller shaft center bearingjournal - with Loctite(version without slidel

46 (33172l52l123 (8el81 (sel

71 (511

20 (14.51

( '

2612 . . .. Center mount to body

\

26_A2 PROPELLERSHAFT

Tightening Torque Type |

". (ft. tbs.l

13

31 FRONT AXLE

Model Series:

Front axle and suspension . . . t . t \ . ! . r . . . .Control armsandstruts . . :S. . . . .Wheel bearingsSpring strutsShock absorbersCoil springs

l^ Since 1987 Models:O11r 'r 'v, l+.,113'E 30 '5'E28 '6'E24 '7'E92

31 101220313233

, . -. i.

Page Page Page Page

.631 -731-631 -731-632 -732-632 -732- 632 - 733-4 -4

31 -1-2-2-3-3-4

- 331- 331-332-332- 332-4

Page

- 531

- 531- 531- 532-4

FRONT AXLE '7'Series

31 10 ... Front Axle and Suspension

Track width with car in normalposition (see page 32 - 1) anda wheel rim offset of

22 mm mm (in. l 1429 (s6.2601 1506 (5e.2e11

35 mm mm (in.) 1405 (55.3571

Height with car in normalposition (see page 32 - 1t.,measured from lower edgeof wheel house to wheel rimflange at center of wheel

14" r ims mm (in. l 570 r 10{.22.458 10.394)

563 r 10122.165 10.3941

579 r 10122.7951 0.3941

585 r 10(23.031r 0.394)

165 TR 390 rims mm (in.) 577 t 10122.716t 0.3941

593 r 10|.23.3461 0.3941

598 r 10(23.543 t 0.3941

Difference of deviation fromnominal value for all wheelsamong each other mm {in.l max. 10 (0.3941

FRONT AXLE

Max. axial spring travel of ballpin with max. wear and testingforce of 1200 N (265 lbs.l mm (in. l

Friction torqus of ball pin Nm (ft lbsl

Strut mount: play betweencentering sleeve and stop pad mm (in. l

Control arm bracket: playbetween centering sleeveand stop pad mm (in.l

Axial wheel bearing play mm ( in. l

LubricantVolume per wheel hub

Grease in grease capVolume

gr.

gr.

1.4 (0.0551

0.4. . .4 {0.3 . . .31

> 0. . . max.0.05F O...max.0.0020)adiust acc. to rapairmanual instructions

Retinax A50

31 12... Control Arms and Struts

0.8 .. . 1.8 (0.031 ...0.0711

o.7 . . .1.7lo.o27 ...0.066)

31 20... Wheel Bearings

bearing assembly lubricated for servicc life - cannot be disassembled

Max. axial runout of wheel hub mm (in.l 0.1 (0.004)

31 31 ... Spring Struts

31 32 ... Shock Absorbers

20.. .25 (1.2. . . 1.51 30.. .35 {1.8. . .2.1f

Oil filling volume between springstrut and shock absorber cartridge(all approved engine oilsl- excluding gas pressureabsorbers cm3 (in.3l

Only install shock absorberswith same codes on one axle

BMW No. (code on hexagonl

Shock absorber test values

733 i: 1 124101 (wl735 i: 1 128 806 (8)

see Service Information of Gr. 37

318 i : 1 125150(sl1125 474ltl

325 e: 1 125 151 (pl1125 475 (ul

1124 tt48 (o)524tdl112e 586 (Fl

1 126 643 (yl

FRONT AXLE

31- 4

Rubber rings (A = top, B = bottoml forsprings with red color code

lmportant!Only install pairs of springs with same BMWnumber (located on end of spring) and samecolor code (either with or without red paintstripe) on one axlel.Refer to spare part microfiche for cross ref-erence of springs according to vehicle typeand, if applicable, special equipment such asair conditioner, sport suspension, etc. as wellas antroduction dates.

The BMW number on tho spring can be used tofind th€ spare part number and consequently thespring belonging to a vehicle acc. to the sparepart microfiche.

1. !ryine with red cotor codeAdd 1 to number on spring, e.g. 1 1ZS 392EiEie part number 1 t2S 333

2. Spring without rdd color codeAdd 2 to number on spring. e.g.= spars part number

1 12s 3321 125339

'7'Series

124 100

31 33 ... Coif Springs

A1 124 6541128522

FRONT AXLE


'3'Serios - E 30


Track width with car loaded downto normal position and rim offset

of 35 mm (1.378")of 30 mm (1.181") - M 3

mm (in.)mm ( in. l

Height (lower edge of wheel houseto rim flange at center of wheel)with car loaded down to normalposition (see page 32 - 11

325 iM3

mm (in. lmm (in. lmm (in. l

Max. difference of deviation fromnominal value among all wheels mm (in.l

31 12... Control Arms and Struts

1405 {55.31511412 (55.590)

s70 r 10|.22.4p-1t 0.3941565t10122.24410.39415s6 r 10 (21.890 r 0.3941

Max. axial spring travel of guideballjoint pin with max. wear mm (in.)

at test force of N (lbs.) 1200|.2641

c€-

,rt:t'

FRONT AXLE


'3'Series - E 30


Lubricant Bearing unit is lubricated for its service life - not to be disassembled

Max. axial runout of wheel hub mm {in.l 0.1 (0.004)


Oil volume between spring strutand shock absorber cartridge(all approved engina oils)- excluding gas pressure absorbers cc 20 . . .25

31 32... Shock Absorbers

Only instal! shock absorbers with same codeon one axle.

1 131 111 lV M3:2 225397 lT M3: Alwaysreplacebothabsorbers11310771O

Shock absorber cartridge BMW No./code(on upper hexagon) 11254751u

11251511p

Shock absorber test values See Service Information of Gr. 37

H€

FRONT AXLE


5'Series - E 28


Track width with car loaded downto normal position (see page 32 - 11and rim offset of 22 mm (0.866"1 mm (in.l 1429 (56.260)

Height with car loaded down tonormal position (see page 32 - 1){lower edge of wheel house torim flange at center of wheell

14" wheel rims mm (in.) 563 r 10122.165t 0.3941

165 TR 390 wheel rims mm (in.l 577 !10122.716 r 0.3941

Max. difference of deviation fromnominal value among all wheels mm (in.) 10 (0.3e41

31 20 ... Wheel Bearings

Lubricant Bearing unit is lubricated for itscomplete service life - not to bedisassembled.


Oil filling between spring strutand shock absorber cartridge(all approved engine oilsl- excluding gas pressure absorben cc 30 . . .35

[' Y

FRONT AXLE


'5'Series - E 28


Only install shock absorbers with same codeon one axle.

M 5: Always replace both shock aborbers.

Shock absorber cartridgeBMW No. / code(on upper hexagon)

Standard 1132369/L11244481o11242941n11252751w

M5: 2225 895 / T

Shock absorber test values see Service Information of Gr. 37

{

FRONT AXLE


'6'Series - E 24


Track width with car loaded downto normal position (see page 32 - 11and rim offset of

22 mm (0.866"1 mm {in. l22mm (0.866") -MG mm ( in. l15 mm (0.590") - M 6 mm (in.)

1429 (56.260)1431 (56.338)1445 (56.8901

Height (lower edge of wheel houseto rim flange at center of wheel)with car loaded down to normalposition (see page 32 - 11

14" wheel r ims mm {in.) 579r10122.7s5r0.394)

165 TR 390 wheel r ims mm (in. l 593 r 10 {23.346 r 0.394}

M 6: mm ( in.) 584r10122.992t0.394)

210 TR 415 wheel r ims - M 6 mm (in.) 593 r 10 (23.346 r 0.3941

Max. difference of deviation fromnominal valus among all wheels mm {in.l 10 (0.394)

31 12... Control Arms

Max. axial spring travel of ballpin with max. wear mm (in.l 1.4 (0.055)

t : t r

FRONT AXLE


'6'Series - E.24


Lubricant Bearing unit is lubricated for its complete service life - not to be disassembled

3t 21 ... Steering Knuckles, Wheel Bearings and Hubs

Max. axial runout of wheel hub mm (in.l 0.1 (0:0041


Oil filling between spring strutand shock absorber cartridge(all approved engine oils)- excluding gas pressure absorbers cc 30 . . .35


Only install shock absorbers withsame code on one axle.

M 6: Always replace both absorbers.

Shock absorber cartridgeBMW No. / code (on upper hexagonl 11266431v

M6 2225 016 / c

absorber test values see Service lnformation of Gr. 37

ar!

FRONT AXLE



?'Series - E 32

Track width with car loaded downto normal position (see page 32 - 11and rim offset of

15 mm (0.590"1 mm (in.l 1540 {60.630}

20 mm 10.787"1 mm {in.) 1530 (60.2361

Height (lower edge of wheel houseto rim flange at center of wheel)with car loaded down to normalposition (see page 32 - 1l andrim offset of

15 mm (0.590") mm (in. l 600 (23.6221

20 mm |,0.787"1 mm (in.l 588 (23.150)

Max. difference of deviation fromnominal value among all wheels mm (in.l 10 (0.394)

31 12... Gontrol Arms and Thrust Struts

Max. axial spring travel of ballpin with max. wear mm (in.l 1.4 (0.0551

tI

( \ '

FRONT AXLE


7'Series - E32

31 20 ... Wheel Suspension

Lubricant Bearing unit is lubricated for itscomplete service life - not to bedisassembled

31 21 ... Steering Knuckles, Wheel Bearings and Hubs

Max. axial runout of wheel hub mm (in.l 0.1 {0.004)


Oil filling between spring strutand shock absorber cartridge(all approved engine oils)- excluding gas pressure absorbers cc 20+5

t t '

FRONT AXLE ?'Ser ies -E32

from 1987 models on

Only install shock absorberswith same code on one axle.

Shock absorber cartridgeBMW No. / code (on upper hexagonl

Standard


1 132540 lb

see Service Information of Gr.37

31-A1 FRONTAXLE

Tightening Torque

\

Nm (ft. lbs.l


Front axle carrier to body

Control arm to front axfe carrier{tightened with car in normalposition*l

Gontrol arm (balljointl to frontaxle carrier

Strut to front axle carrier(tightened with car in normalposition*)

* Gar in Normal Position:Car loaded down with 2 x 68 kg (2 x 150 lbs.)on front seats (seats in center positionl,1 x 68 kg (1 x 150 lbs.l on center of rear seat(not for coupes and M 3), 1 x 21 kg (1 x 46lbs.l in middle of trunk or 14 kg (31 lbsl forcoupes and M 3 as well as full fuel tank.

E23E 28,E 24 since 5.82,E32

E30

8s (61177.5 (561

85 (61)

135 (e8l

{' ' t ,\ - :

12 ,.. Control Arms and Struts

Control arm to spring strut ortie rod arm

Control arm bracket to engine @rraer

Thrust strut to body (tightened withcar in normal position - see page 31 - A 1l

Thrust strut to tie rod arm

Thrust strut to connecting pipe(tightened with car in normal position- see page 31 - A 1l

Connecting pipe to body

Connecting pipe prop to body

Connecting pipe to thrust strut mount

Strut to tie rod arm

E30

E30

E 28, E 24 since 5.82

E 28, E 24 since 5.82E32

E32

E32

E32

E28,E 24 since 5.82

E23

65 (47)

42 (301

130 (e4l

85 (61.5)93 (671

127 lezl

127 lezl

5e (42.51

60 (431

85 (61.51

31 - A2 FRONT AXLE

Tightening Torque Type I Nt (ft.lbs.)

31 -A3 FRONTAXLE


E 28, E 24 since 5.82,E30,E32

E23

Atl

E23E 28, E 24 since 5.82, E 30

2e0 (210)

see tightening specifi-cations in repair man.

22116l

80 (58165 (471

3121 ... Wheel Hubs

Collar nut (bearing unit)

Castle nut


Spring strut mount to wheel house

Spring strut shock absorber to mount

3132 ... Shock Absorbers

Spring strut shock absorberscrew-on ring

(!' I

-- . - . {\t

Nm (ft. lbe.l

Stabilizer

Holder to front axle carrier or body

Support to control arm and sbbilizer(tightened with car in normal position- see page 31 - A 1l

Thrust rod to spring strut and stabilizer(yellow chrome plated){white chrome platedl(whitel

Thrust rod to stabilizer or springstrut

Pivot to control arm

M8M10

25 (18150 (361

20114.5133l24l5e (42.51

42 (301'59 (42.51

42 {301

31 -A4 FRONTAXLE

Tightening Torque

E 28, E 24 since 5.82, E 23,830,E32

E23E23

E28E 28,E 24 sincs 5.82E32,E 24 since 5.82,E28

830M3

E30

I

I

15

32 STEERING AND WHEEL ALIGNMENT

Model Series: Atl

Page

Testing conditions for wheel alignment . . 32 - 1Wheel alignment - front axle . - zWheel alignment - rear axle .Steer inggear. . -5Power steering pump - o

Since 1987 Models:3 ' ,E30 ' .5 ' ,E28 '6 'E24 '7 ' ,E32

32 00

Page

-1- 331- 333.3it4- 334

Page

-1- 531- 533- 534- 535

Page Page

-1 -1- 601 -731- 603 - 733-604 -734-605 -735

1341

STEERING AND WHEEL ALIGNMENT

32- 1

* Car loaded down to normal position

TESTING CONDITIONS FOR CHECKING/ADJUSTING WHEEL ALIGNMENT

1.2.3.4.5.6.

Specified wheel rims and tires.Uniform tire treads.Specified tire inflation prsssure.Specified wheel bearing play.Specified height level.Car loaded down to normal position*

See Group 36

See Seruice lnformation of Gr. 36See Group 31See Group 31/33

I'6'Series, M 3

2 x 68 kg (2 x 150lbs.l on front soats(seats in middle positionl;1 x 14 kg (1 x 31 lbs.) in trunk (middleland full fuel tank.

2 x 68 kg (2 x 150 lbs.l on front seats(seats in middle position)i1 x 68 kg (1 x 150lbs.l on rear seat(middlel;1 x21kg (1 x 46 lbs.l in trunk (middle)and full fuel tank.

/ 't \


32-2

'3 'Series '5'Series '6'Series '7'Series

32 00 ... Front Wheel Alignment

See testing conditions on page 32 - 1.

Total toe o

-mm ( in.)

oo 18' t5 ' oo 18' t5 ' oo 4.s '+19,

2.0 t 0.6(0.07e !0.0241

2.0 r 0.6 (0.079 *0.0241 i;'"ira'g I g:glgrTRX tires mm (in.) 2.1 t 0.6 (0.083 t0.0241 '''l,ilf. 1 8:Bt8r

Camber o - 40' t30' - 20' t30' oo t 30'

Toe difference angle with insidewheel at 20o lock o - 10 40' t3o' - 1() 50', t3o', - lo 40' t30'

King pin anglewith 10o wheel lockwith 20o wheel lock

ooo

130 51', t 30',130 37',t 30',

120 + 30', 1 10 20', t 30',

Gasterwith 10o wheel lock o

with 20o wheel lock oBo 30't 30'go 46',t 30',

8() r 30',go 15', t 30',

go 57', t 30'go 35',t 30',

Max. caster deviation

Front wheel disPlacement

o

o

00 30'

oo rts'

{'


32 00 .,. Front Wheel Alignment

Maximum wheel locklnside wheel o approx.41.3 approx.43.7 approx. 4i|

Outside wheel o approx.33.9 approx.33.1 approx. 33

Turning circle dia. m (ft.) approx. 10.5 (34.4) approx. 10.9 (35.7) approx. 11.6 {38.0}


See testing conditions on page 32 - 1.

mm {in.l

TRX tires mm (in.l

Camber, negative (incl. elasticity) o

Geometrical driving axis o

oo lB' t 7'

2.0 r0.8 (0.079 r0.0311

2.1 t0.8 (0.083 r0.031)

oo r ts'

-2|J 20',x30'

32 00... Rear WheelAlignment

- 10 so't30' -20 20't30'

l


32 13... Steering Gear

Code number 7832 955 109 8052 955 206 8052 955 213 8051 955 101

Ratio 14.5: 1 13.5 : 1 15.7 z 1

Oilgrade see Service lnformation of Group 00

Oil volume cc approx. 1200 approx. 1200(2000 for cars withbrake pressurehydraulic supportl

approx.2000

Pressure point (friction torquel Nm (ft. lbs.l 1.0 ... 1.210.72... 0.871

Friction torque rise (pressurepoint) on steering spindle ascompared with torque outsideof center position Nm (ft. lbs.l 0.3 ... 0.4 (o.22... 0.291

I\{


32 41 ... Power Steering Pump

Gode numbera

, ' ' , 7681 955 110 7682955270

Ratd pressure at engineidle speed (max.) bar (psil

t

110.. . 120 (1565.. . 17051 r30...t40 fi 850 ... 19901

Narrow drive belt size mm 318 i : 9.5 x 810325 ez 9.5 x 825

528 e: 9.5 x.825524 tdz 9.5 x 86553ll i-535 i:9.5 x 900

9.5 x 900 9.5 x 912

/ 't

F,,l

STEERING AND WHEEL ALIGNMENT '3'Series - E 30



Refer to testing conditions on page 32 - 1.

Total toe o

mm ( in.)

Camber* o

o

oo

oo

Toe difference angle'with 20o inside wheel lock

Kingpin inclination*with t 10o wheel lockwith t 20o wheel lock

Caster*with t 10o wheel lockwith t 20o wheel lock

Displacement of front wheels o

* Max. difference in tolerances between left and right: 30'.

oo 18' t 5 ' oo 17' * s'

2.0 t 0.6 (0.079 r 0.024) 2.0 r 0.6 (0.079 r 0.0241

- 10 40', t30' - 10 12', +30',

130 52',t 30',14() 15',t 30', 140 1s',t 30',

8() 30't 30'go 46', t 30'

go B' t 30'

t4

k



'3'Series - E 30 M3

Maximum wheel lockInside wheel o approx. 41.3 approx.38

Outside wheel o approx.33.9 approx.32.8

Turning circle m (ft.l approx. 10.5 (34.41 approx. 11.1 {36.4)

STEERING AND WHEEL ALIGNMENT '3'Series - E 30

from 1987 models on

32 00 ... Rear Wheel Alignment

oo 23't7',

Refer to page 32 - 1 for testing conditions.

Total toe o

mm (in. l

Camber* (negative) o

oGeometrical operating axis


oo 18' t 7'

2.6 t 0.8 (0.102 t 0.031)2.0 r 0.8 (0.079 r 0.031) 2.9 r 0.9 (0.114 r 0.0351

- 20 15', +30',- 10 so' t3o'

t

E{



'3'Series - E 30

3213... Steering Gear

Oil grade see Group 00 of OperatingMaterial Specif ications

Oilvolume in hydraulic circuit cc approx.1000


Rated prsssure at engine idlespeed bar (psi) max. 110 . . . 120 (1565.. . 1705)

Narrow drive belt size mm 9.5 x 825

M3 mm 9.5 x 810

I. ,



'5'Series - E 28



Totat toe o

rr fi"J

oo lB' t 5 '

2.0 t 0.6 (0.079 t o.o24l

TRX 390 wheel r ims mm (in. l 2.1 r 0.6 (0.083 ! O.O24l

Camber* o -20' t30'

Toe difference angle'with 20o inside wheel tock o - 1o so' t30'

Kingpin incl ination*with 1 10o wheel lockwith t 20o wheel lock

oo

110 57' , t 30' ,12() r 30',

Caster*with t 10o wheel lock o

with t 20o wheel tock ogo + 30'go 20' + 30'

Displacement of front wheels o 00 r 15'

I Max. difference in tolerances between left and right: 30'.

t -t



'5'Series - E 28

32 00 ... Wheel Alignment

Maximum wheel lockInside wheel o approx.43.7

Outside wheel o approx.33.1

Turning circle m (ft.) approx. 10.9 (36)

STEERING AND WHEEL ALIGNMENT '5'Series -E28

from 1987 models on


oo 1B' t 7'


Total toe o

mm ( in. l

TRX 390 wheel rims mm ( in.)

o

o

Camber* (negative)

Geometrical operating axis


2.0 r 0.8 (0.079 r 0.0311

2.1 t 0.8 (0.083 t 0.031)

tI r\t



'5'Series - E 28

3213... Steering Gear

Oilgrade see Group 00 in Operating Material Specifications

Oi lvolumein hydraulic circuit cc approx.1200

with H 31 system cc approx.22OO

Pressure point friction torque Nm (ft lbsl 1.0 . . . 1.2 10.72.. . 0.871

Ratio 14.5 :1

M5 13.5 : 1


Rated pressure at engine idlespeed bar (psi) max. 110.. . 120 (1565 . . . 17051

Narrow drive belt size528 e mm 9.5 x 825

535i . . .M5 mm 9.5 x 900



'6 'Ser ies -E24



Total toe o

rr fin

18', t s ' ,

2.0 r 0.6 (0.079 t o.o24l

with TRX 390/415 wheels mm (in.l 2.1 r 0.6 (0.083 t o.o24l

Camber* o -20' !30'

Toe difference angle*with 20o inside wheel lock o - 10 so' t30'

Kingpin inclination*with t 10o wheel lock o

with t 20o wheel lock o110 57' ,130' ,120 t30',

Caster*with t 10o wheel lock o

with t 20o wheel lock o80 t 30'go 20' t 30'

Displacement of front wheels o 0(' t 15'


.1



'6 'Ser ies -E24


Maximum wheel lockInside wheel o approx.43.7

Outside wheel o approx.33.1

Turning circle m (ft.l approx. 10.9 (36)


from 1987 models on

'6'Series - E 24

32 00 ... Bear Wheel Alignment


Totaltoe o

Camber* (negative) o

Geometrical operating axis o


2.0 r 0.8 (0.079 t 0.0311

2.1 r 0.8 (0.083 r 0.0311

\ l



'6'Series - E 24

3213..: Steering Gear

Oil grade see Group 00 in Operating Material Specifications

Oi lvolume cc 2200

Pressure point friction torque Nm {ft lbs)

Ratio 13.5:1


from 1987 models on

'6'Series - E 24


Rated pressure at engine idfespeed bar (psi)

Narrow drive belt size mm

110.. . 120 (1565.. . 1705)


32 -731

'7'Series -E32



Total toe o

rr (,n

oo lB' t sf

2.2 !0.6 (0.087 r 0.024)

with TRX 415 wheels mm (in.) 2.4 !0.6 (0.094 t 0.0241

Camberi o - 13' ,130' ,

Toe difference anglewith 20o inside wheel lock o - 10 40' t30'

Kingpin incl inationtwith t 10o wheet lockwith + 20o wheel lock

oo

110 53' , t 30' ,110 55' , t 30' ,

Casteriwith t 10o wheel lock o

with t 20o wheel lock ogo 5' t 30'80 20' t 30'

Displacement of front wheels o oo r ls'


[ ' (


32 -732

'7'Series - E 32


Maximum wheel lockInside wheel o approx.43

Outside wheel o approx.33

Turning circle m (ft.) approx. 11.6 (38)


32 -733

'7'Series -E32



Total toe o

rr fin

oo 18' t 7'

2.2tO.8 (0.087r 0.031)

with TRX 415 wheels mm (in. l 2.4 r 0.8 (0.094 t 0.0311

Gamberr (negativel o -zo zo' tgo'

Geometrical operating axis oI oo tts'

* Max. difference in tolerances between left and right: 30'

(:{


32 -734

'7'Series -E32

3213... ZF Power Steering Gear

Ratio 14.5 z 1

Oil grade see Group 00 in Operating Material Specifications

Oil volume in hydraulic circuit cc 2400

Friction torque rise (pressurepoint) on steering spindla incomparison with torque outsideof center position Nm (ft lbsl 1.4 (1.011

25*A1 SHIFT


25 11 ... Shift for Manual Transmissions

Front base to shift console{sheet metal console}

Shift console to transmission(sheet metal console)

Rear shift console to body

25 (181

23 (16.5)

11 (8.01

25 - A2 SHIFT

\ Tightening Torqua Tvpe | rum (ft. tbs.l

25 16 ... Shift for Automatic Transmisions- Version with Cabls -

Cable sleeve to holder, shift consoleand transmission

Clamping screw on transmission

10 (71

11 (81

.aJ

26 PROPELLER SHAFT

ModelSeries

Engine Designation

2611 Deflection torque of universal ioints IPreload of center mountDeflection angles

I\

12

3'4cyl. 3'6-cyl. '5'6+yl.

M 20lM 21

Page

26-2

Page

26 -1

Page

26-la

'5'6+yl.

M30

Page

26 -2a

'6' E 24 ',7' E 23

Pagp Page Page

26 -3 26-4 26.5

t

E

PROPELLER SHAFT

'3'ModelSeries - 4 Cyl.

26-1

4-speed ManualTransmission


AutomaticTransmission

26 11 ... Propeller Shaft

Deflection torqus of universaljoints Ncm (in. 20.. .70 (1.7. . .6.01

Preload of center mount infonruard direction mm (in.) 4 . . .6 (0.157" . . .0.236"1

Deflection anglesJoint discs -25',... + 35',

Universal ioint, center

Universal joint. rear

- 50' . . . + 10'

- 10' . . . + 50'

Deflection Angle

I poshiv (+l

/ negativ (-)

- -} - - r r r - . . - t - - -

\ (

- 27' ... + 33'

PROPELLER SHAFT

'3'ModelSeries - 6 Cyl.

26- la


S-speed ManualTransmission


26 11 .., Propeller Shaft

Deflection torque of

Preload of center mount infonrard direction mm (in.)

20 . . .70 (1.7 . . .6.01

4 ... 6 /.0.157"... 0.236"1

Deflection anglesJoint discs - 47' ... + 13, - 49' . . . + 11'

Univarcaljoint, center - 10 10, . . . - 10, - 10 09, .. . - g,

Universal joint, rear - 10' ... + 50' - 10' ... + 50'

Deflection Angle

/ positiv (+)

-:A-t -\

/

negativ (-)

! - - - -A-

.1/t'2'"'

\

PROPELLER SHAFT

'5' Model Series - 6 Cyl. - M 20 | M21

26 -2




26 11 ... Propeller Shaft

Deflection torque ofuniversaljoints Ncm (in. lbs.l 20 . . .70 (1.7. . .6.01

Preload of center mount infonruard direction mm {in.l 4 . . .6 (0.157" . . .0.236"1

Deflection anglesJoint discs - 16', ... + 44',

Universal joint, center

Universal joint, rear

- 38', ...+22',

- 18', ... + 42',

Deflection Angle

/ positiv (+)

-:A-t -

negativ (-)

r - I I iO-

-20' . . .+ 40'

\

PROPELLER SHAFT

'5' Model Series - 6 Cyl. - M 30

26-2a




Deflection torque ofuniversalioints Ncm (in. lbs.l

Preload of center mount infonrvard direction mm (in.l

20.. .70 (1.7 . . .6.01

4 . . .6 (0.157" . . .0.236. ' )

Deflection anglesJoint discs 50' ... 10 59', 1( ' 03'.. .20 03,

Universal joint, center - 02' ... + 58' - 07' ... + 53'

Universal joint, rear - 46' ...+ 14' - 6', ... + 14',

Deflection Angle

/ positiv (+)

T---=-- '(

A

nssativ (-l

-;=.,-

i .$

PROPELLER SHAFT

'6'Model Series

26-3




2611 ,.. Propeller Shaft

Deflection torque of universaljoints Ncm (in. lbs.l 20.. .70 (1.7. . .6.0)

4 . . .6 (0.157". . . 0236"1Preload of center mount inforward direction mm (in.l

Deflection anglesJoint discs 10 03' ... 20 03'

- 07' ... + 53',

- 46' ... + 14',

Universal joint, center

Universaljoint, rear

Deflection Angle

I, ! l - - -t ; "s i t ive( i -G

50'., . 10 59',

t:

STEERING AND WHEEL ALIGNMENT 7'Ser ies -E32

32 -735


130 r 10 (1850 r140)Rated pressure at engine idlespeed bar {psi)

32 41 ... Narrow Drive Belt

Size mm

II

32 _ A 1 STEERING AND WHEEL ALIGNMENT

Tightening Torque Nm {ft. lbs.)

Steering Gear

Steering ggar to front axle carrier E23

E 28, E 24 since 5.82,E30,E32

E 28, E 24 since 5.82, E 32

42 (301

42 {30)

80r8(58r6)

(

Steering Gear (with Hydraulic Boosterl

Locknut for adjusting scrow

Oildrain plug

Ring nut:2.5 mm snap ring wire diameter3.5 mm snap ring wire diameter

Valve body to housing

Pressure piece cover

Pipee (hollow union boltsl onsteering gear

Arl

Ail

27 (1e.51

42 (30)

120 (871150 (108.51

18 (13)

18 (13)

10 (7120 (14.51

M10M12

E30E30

E30

E30

E30E30

32. A2 STEERING AND WHEEL ALIGNMENT

Tightening Torque Type I Nm (ft.lbs.l

tt

32 - A 3 STEERlNG AND WHEEL ALIGNMENT


60 (431

75 (54)

36.5 r 3.5 (26.5 r 2.51

14 (10)

at least 140 (1011at least 180 (13015e (43)

42 (30)

Stearing Arms and Tie Rods

Tie rod to ball joint {lock nutl

Tie rod to rack

Tie rod castle nut/self-locking nut

Tie rod clamping screw {tightenedwith car in normal position - seepage31-A1l

Steering drop arm to steering gmr(torque value can be exceededuntil there is correct alignmentwith the lockplate)

Steering guide arm to front axlecarrier

3221 ... Steering Arms and Tie Rods

Tie rod arm to spring strut(bolt cement Loctite 2701

Tie rod arm to controlarm

Strut to tie rod arm

r Threads of bores and bolts cleaned {with a tapper}

t--I

M3E28,E 24 since 5.82,E23E32

M3E28,E 24 since 5.82E32

E23E32

)

30l22l "62 (451 *110 (801 r

65 (47)86 (61.51e3 {671

85 (61.sle3 (671

32 * A4 STEERING AND WHEEL ALIGNMENT

Tightening Torque Type I Nm {ft. tbs.}

. . . qnd lraa al nrarca

32 - A 5 STEERING AND WHEEL ALIGNMENT


Steering Column

Univenal joint or joint disc tosteering gear

Universal joint or joint disc tosteerang spindle

Console for steering wheel controland control lever to clamp(see Repair Manual for assemblingproceduresl M8x65

M 1O x22M 10 x 22left

Console for steering wheel controlon instrument panel carrier andpedal base M I

E 30, E 28,E 24 since 5.82,E23,E32

AI

22 (161

22 (16t.

22116l20 (14.5)I (6.0)

6

3231 ...

32 33 ...

3234.. .

Steering Column

Bolt on console for steering wheelcontrol M

M

Clamp or holder for outer tube

Airbag:Steering column to holderSteering column to instrument panelSteering column to lever

Steering Wheel

Steering wheel to steering spindle

Airbag unit to steering wheel

Front sensor on wheel house

E 28, E 24 since 5.82E23

AilE23

8x11010 x 170

22116l27 (le.s)

22116l10 (71

18 (13122116l14 (101

AtlAtlAtl

80 (58)

5 (3.51

10 (71

32 - A 6 STEERING AND WHEEL ALIGNMENT

Tightening Torque Type | rurn (ft. tbs.l

32 _ A7 STEERING AND WHEEL ALIGNMENT


Power Steering Pump

Power steering pump console tocrankcase (check shims - seeService Information of Gr.32)

Hose connections on powersteering pump and steering gear

Hoss connections on power flowregulator

16

33 REAR AXLE

E 30, E 29,E24,E23 Page

' ' -

Output shaft .Wheel bearingsShock absorbersCoilsprings

M3,M5,M6,E32 Page

Rear axle in general . . 33 - 11Final drive - 12Drive pinion and ring gear - 13Differential - 14Outputshaft . -15Wheel bearings - 16Shock absorbers - 16Coilsprings - 16

33 0010121321415253

12344556

33 0010121321415253

, .

REAR AXLE


a) 318 ib)318 iA

al 325 eb) 325 eA

a) 528 e la) 533 ib)528 eA f UlSea in

lc)535id)524 tdA ld) 53s iA

al 633 CSib) 633 CS|Ac) 635 CSid)63s csaA

a) 733 ib) 733 iAc) 735 id) 735 iA

33 00 ... Rear Axle in General

Track width with car in normalposition {see page 32 - 1l anda wheel rim offset of

22 mm (0.866") mm (in. l 1452 (57.1651 1sl1 (5e.4881

35 mm (1.378") mm (in. l 139e (55.07e)

Height with car in normalposition (see page 32 - 11,measured from lower edge ofwheel house to rim flange atcenter of wheel mm (in.l 540 t 10

l2r2601 0.3941535 r 10(2r.063 r 0394)

501 r10119.724t0.394) s46 r 10(2r.496 r 0.3941

518 r 10(20.394 t 0.394)

Max. difference in height fromnominal value among all wheels mm (in.l 10 (0.394)

REAR AXLE


a) 318 ib)318 iA

al 325 eb) 325 eA

a) 528 ebl 528 eA

dl 524 tdA

al 533 ib) 533 iAc) 535 id l535 iA

a) 633 CSibl633 CS|Acl 635 CSid)635 CS|A

al 733 ib) 733 iAc) 735 id) 735 iA

33 10... Final Drive

Oilgrade see Service Information of Group 00

Oi lvolumefor oil change (approx.){up to overflow in filleropeningl ltr. (pts.l 0.e (1.e} 1.7 (3.6)

for initial filling ltr. (pts.l 1.312.71 1.7 (3.61

REAR AXLE


al 318 ib l318 iA

al 325 eb) 325 eAc) 325 id l325 iA

al528ebl 528 eA

dl 524 tdA

al 533 ib) 533 iAcl 535 id)535 iA

al 633 CSib) 633 CSiAc) 635 CSid) 635 CS|A

al 733 ib l733 iAcl 735 id l735 iA

33 12 ... Drive Pinion and Ring Gear 1l from 1984 models on 2l from 1985 models on

Code H9H 21)

blHl2l

H27H 33 1)

c,dl H 35

a,b) H 33d) H34

H34 a,bl H 34c,d) H 30

a,b) H 34c,d) H 30

Ratio 3.643.91 1)

bl4.10 2)

2.792.93 1)

c,d) 3.73

a,bl 2.93dl 3.25

3.25 a,b) 3.25c,dl 3.46

a,b) 3.25c,dl 3.46

Number of teeth 40111$f i l11

bl4111021

39114411141l-

cdl 41111

a,bl 41114d) 39112

39112 a,bl 39112c,dl 45/13

a,bl 39112c,d) 45/13

Backlash mm (in.l 0.06 . . .0.13 (0.0024 . . .0.00511

Ring gear installing temp. oC (oFl 80.. . 100 1176.. .2121

Max. drive flange radial runout mm (in.l 0.07 (0.00281

Shaft seal friction torquo Ncm {in. lbs.l approx. 20 11.71

REAR AXLE


a) 318 ib)318 iA

al 325 eb) 325 eAc) 325 id) 32s iA

al 528 eb) 528 eA

dl 524 tdA

al 533 ib l533 iAc) 535 id)535 iA

al 633 CSib) 633 CS|Ac) 635 CSid) 635 CS|A

a) 733 ib) 733 iAc) 735 id l735 iA

33 13 ... Differential

Play between shim anddifferential side gear mm (in.l 0.03 ... 0.1 (0.0012 ... 0.00391

33 14 ... Final Drive with Limited Slip Differerrtial

Slip torgue with one eachdifferential side gear held anddriven Nm (ft.lbs.l 30.. .50 122.. .361 50.. .75 (36 . . .541

110.. . 130(80.. . e4)

Outside plate thicknass(optionall mm {in.l 1.9 (0.0751 l2.O lO.O79l 12.1(0.083)

Inside plate thickness mm (in.l 2.0 (0.0791

33 21 ,,. Output Shaft

Design with constant velocity joints

Grease volume per joint(grease part of "dust covsr"repair kitl grams 80 120

Adhesive for dust covers red Bostik 1513 (optionally red Epple 4851)

tcompound for endand caps Epple 39 or Curil K

REAR AXLE


al 318 ib) 318 iA

al 533 ib) 533 iAcl 535 id) 535 iA

al 733 ib l733 iAc) 735 id) 735 iA

al325eb) 325 eAc) 325 id) 325 iA

al 528 eb) 528 eA

dl 524 tdA

al 633 CSibl633 CS|Acl 635 CSid) 635 CSaA

33 41 ... Wheel Bearings 1l since 1.84

angular contact ball bearings, double row, permanent lubrication, not dismantableType

33 52 ... Shock Absorbers

Only install shock absorbers ofsame make and same type onone axlel

Code no.


126 473125079

1125476 | 11275271 125 156 | t 125802

1 126 645 a, bl1 125 380a, b)1 129242 1lc, d)1 128 815

REAR AXLE


a) 318 ib l318 iA

al 325 eb) 325 eAc) 325 id) 325 iA

al 528 eb) 528 eA

d) 524 tdA

al 533 ib) 533 iAc) 535 id) 535 iA

al 633 CSibl633 CS|Ac) 635 CSid) 635 CSaA

al 733 ib) 733 iAcl 735 id l735 iA

33 53 ... Springs 1) since 9.&d 2) until 9.83 *) only appl. to Bilstein

Always install springs in pairson one axle with same BMWpart number (on end ofspring) and same color code.

Also refer to parts microfiche.E 30: part numbers are for pairc.

I 057 133I 057 335 *l9057336 1)

9 057 349I 057 337 *l

1 127 85111287101125328 r )

1 127 8381 127 851 *)

1 127 788 2l1125328

1 127 151 2la,b) 1 128 632c,d) 1 127 151

Color code depending on springforce (face of lower springretainer)

Upper rubber ring for coilsprings with red color code

l xred1 x white

none

1 x red or none

1 124591 1 117 671

Lower rubber ring for coilsprings with

red color code 1 127 224

white color code 1 127 516

no color code 1 127 218

M3Convertible

735i - E32735iA -E32

REAR AXLE

33-11

Track width with car loadeddown to normal position (seepage 32 - 1) and wheel rimoffset of

35 mm (1.378"1 mm (in.)

22 mm (0.866") mm (in. l

15 mm (0.590") mm (in.l

20 mm (0.787"1 mm (in.l

Height (lower edge of wheelhouse to rim flange at centerof wheel) with car loadeddown to normal position(see page 32 - 1l mm ( in. l

Max. difference in deviationfrom nominal value among allwheels mm (in.)

33 00 ... Rear Axle in General

13e9 (55.0791

1470 157.8741

1559 (61.378)

510 t 10(20.079 t0.3941

508 r 10{20.000t 0.3941

556 r 10(2r.89010.394)

522 t10(20.55r r 0.3941

REAR AXLE

33-12

M3 M5 M6 735i -E32735 iA - E32

33 10 ... Final Drive

Oi lgrade see Service Information of Group 00

Oi lvolumefor oil change (filled untiloverflow in filler opening) ltr. (pts.) 1.7 (3.6) 1.9 (4.0) 1.7 (3.6)

for initial filling ltr. (pts.) 1.7 (3.61 1.e (4.01 1.7 (3.6)

REAR AXLE

33-13

M3 M5 M6 735 i -E32735iA -E32

Code H21 H52 H24

Ratio 4.10 3.91 3.64

Number of teeth 41110 43111 40111

Backlash mm (in.l 0.06 ... 0.13 {0.0024 ... 0.00s1)

Ring gear installing temp. oC (ofl 80.. . 100 1176.. .2121

Max. input flange radial runout mm (in.l 0.07 (0.0027)

Shaft seal friction torquo Nm (ft. lbs.) approx.0.20 (0.141

REAR AXLE

33-14

M3 M5 M6 735i - E32735iA -E32

33 12... Drive Pinion and Ring Gear

Pinion bearing friction torqueFAG Nm (ft. lbs.l 2.4211.751 3.70 (2.68) 2.4211.751

SKF Nm (f t . lbs.) 1.90 (1.37) 3.15 (2.28) 1.e0 (1.37)

Timken Nm (ft. lbs.) 2.45 (1.771 3.7312.70l- 2.4511.771

Koyo Nm (ft.lbs.) 1.9s (1.41) 3.s8 (2.5e1 1.95 (1.411

33 13 ... Differential

Friction torque for bothdifferential case bearings

FAG Nm (ft. lbs.l 1.77 |.1.28l- 1.77 11.28l-

sKF Nm {ft. tbs.} 2.20l1.5sl 2.20 (1.5e)

Timken Nm (ft. lbs.) 1.90 (1.371 2.80l2.O2l 1.90 (1.371

Koyo Nm (ft. lbs.l 1.24 (0.90) 1.99 (1.44) 1.24 (0.901

Play between diaphragmspring/shim and differentialside gear mm (in.) 0.03 ...0.10 (0.0012 ... 0.0039)

REAR AXLE

33-15

M3 M5 M6 735 i -E32735iA -E32

33 14... Final Drive with Limited Slip Differential

Slip torque with one each differentialsida gear held and driven Nm (ft. lbs.l

30 . . .50122 ...361 50 ...75 (36 ...3il

110.. . 130(80.. . e4)

Outside plate thickness(optional) mm (in.) 1.9 (0.0751 l2.O l0.O7g',t 12.1(0.0831

Inside plate thickness mm (in.l 2.0 {0.07e1

33 21 ... Output Shaft

Design with constant velocity joints

Grease volume per joint{grease part of "dust covor"repair kitl grams 80 120

Adhesive for dust covers red Bostik 1513 (optionally red Epple 4851)

Sealing compound for endcovers and caps Epple 39 or Curil K

REAR AXLE

33-16

M3 M5 M6 73s i - E32735iA -E32

33 41 ... Wheel Bearings

Type Angular contact ball bearings, double row, permanent lubricationand not dismanuble

33 52 ... Shock Absorbsrs

Only install shock absorbers ofsame make and same typs onone axle

Shock absorber tost values see Service Information of Group 37

33 53 ... Springs

Always installsprings in pairson one axle with same BMWnumber lon end of springland same color code.

See parts microfiche.E 30: part numbers are for pairs.

,.4

t

33_A1 REARAXLE


33 10 . . .Final drive to rear axle carrier

Final drive to 3 rubber mounts

Final drive vibration damper to body

Final drive to rubber mount

33 11 . . .Case cover

Side bearing covers

Oil filler and drain plugs

Electronic speed transmitter to cover

3,5,6 and 7 ser ies

Tser ies -E32

3 series

5,6and7ser ies

Atl

Atl

Atl

All

110 . . . 123 (80 . . . 89)

77.5 (56)

81 . . .90 (59 . . . 65)

80 . . .87 (58 . . . 631

40 . . .50 (29.. . 36)

22 . . .25 (16 . . . 18)

50 . . .60 (36 . . .431

I . . . 10 {6.5 . . .7.0)

33 _ A2 REAR AXLE

Tightening Torque Type I Nt (ft. lbs.)

3312 . . .

33 13 ...

33 17 ...

Flange to driYe pinion

Ring gear to differential case(installsd with Loctite No.270 -always uss new bolts after repairing)

Limited slip differential coverto differential case(installed with Loctite No.270)

Rubber mount to body

M 10 8.8linstalled with Loctite2TOl

Output shaft to final drive anddrive flange

AllM5,M6

M5,M65,6 and 7 series, 325 alA,325 i/A, M3

318 i/A

5 and 6 series

7 series

at least 150 (1081at least 31O 12241

165.. .195 (120.. .141)

100 . . . 110172.. .80)plus torque angle of50.. .55050.. .55 (36.. . / tOlplus torque angle of50 ...60()

30.. .33 122.. .241

43 . . .48 (31 . . .351

50 . . .52 (36.. .381

M8

Atl

33 21 ...

M10 58 ... 63 {.42 ...461

33-A3 REARAXLE


Rear axle carrier with rubber mountsto body

Trailing arm to rear axle carrier(tightened with car in normalposition - seo pago 31 - A 1l

Support bracket to body

Thrust strut to body

Auxiliary control arm to trailingarm and rear axle carrier (tightenedwith car in normal position - seepage3l-A1l

Atl

3 series

5,6 and 7 series

5,6 and 7 series

140.. .155 (101.. .1 12)

67 . . .75 (48.. . Sl

25.. .28 (18.. .201

22.. .24 (16 . . . 171

130.. . 143 (94 . . . 1031

33-A4 REARAXLE

Tightening Torque Type I Nt (ft. lbs.l

33 41 ...

33 52 ...

Rear axle shaft to drive flange(collar nut waxed cloudy whitel

Drive flange hub to autput shaft

Shock absorber to trailing arm(tightened with car in normalposition, seo pago 31 - A 1l

Shock absorber/spring strut tospring retainer Nut and

Spring retainer to wheel house

Shock absorber (mountlto body

Shock absorber to mount Nut and locknut

Stabilizer to trailing arm(tightened with car in normalposition, see page 31 - A 1)

5,6 and 7 series

3 series

3 series5,6 and 7 serier

5 and 6 series7 series

5,6 and 7 series

3 series

3 series

234...260 (169...188)

195.. .210 (140.. .152)

72.. .87 {52.. .63}12s.. .143 (90.. . 103)

22.. .25 (16.. . 18)25 ...30 118 ...221

22.. .24 (16.. . 17)

22.. .24 (16.. . 171

13 . . . 15 {e. . . 11}

22.. .24 (16.. . 171

17

34 001121213341505152

BRAKES

Page

Brakesingeneral . . . .34-1Front wheel brakes - 2Rear wheel brakes (discs) - 3Rear wheel brakes {drumsl - 4

lffii-::::::::::::::::::::':::'::.:' ;l

I

BRAKES


al 318 ib) 318 iA

al 325 ebl 325 eAclM3

al 528 ebl 528 eA

dl 524 tdA

al 533 ib) 533 iAcl 535 id l535 iAe)M5

al 633 CSib) 633 CS|Ac) 635 GSid) 635 CS|Ae)M6

al 733 ib) 733 iAcl 735 id)735 iAe)832

34 00 ... Brakes in General

Brake fluid see Seryice Information of Group 00

Leak test on stopped engina(if applicable, dischargs prossuroreservoir with about 20 fullstop braking actionsl

Force on pedal N (lbs.l 500 (1 101 675 (1491 650 (143)

Equal to line pressuro bar lpsil 50 (710) 50 (7101

Max. permissible pressuredrop within 2 minutes % I

Brake booster tsstForce on pedal N (lbs.) 200l44l 200l44l

e) 150 (331

Line pressure bar (psi) 70...90 (994 ... 12781 90.. . 11011278... 1562)el 50 (7101

t - f\ t

BRAKES


al 318 ib) 318 iA

a) 325 ebl 325 eAc)M3

al 528 ebl 528 eA

dl 524 tdA

a) 533 i la) 633 CSibl533 iA lU)eSa CSiec) 535 i f cl 635 CSid) 535 iA laloss csine)M5 le lM6

al 733 ib) 733 iAcl 735 id) 735 iAel E32

34 11 ... Front Wheel Brakes

Brake pads(always use same type on one axlel

Type Textar T 297 {with Politex}c) Jurid 23812

T 260 FF (with Politex)el Jurid cF 23812 e) Jurid 59b

Min. pad thickness mm (in.l 2.0 (0.0791

Machining limit (always grindboth sides of one axle) mm (in.l 11.1 (0.437) 20.4 (0.8031

cl :23.4l0.ezll

20.4 {0.803) 23.4l0.921la, b l : e) :20.4 (0.803l- 26.4 (1.0341e)28.4 (1.118)

Wear l imit mm (in.) 10.7 (0.421t- 20lo.787lcl 23 (0.9051

20lo.787l 20 lo.787l 23 (0.9061 el 2G l1.o24le) 28 (1.1021

Max. thickness toleranceof brake surfaces mm (in.l 0.02 (0.0008)

Axial runout of brake surface(measured on largest diameterof brake surface)

Disc removed mm (in.l max.0.05 (0.0020)

Disc installed mm (in.l max.0.2 (0.008)

Brake surface finish Ra p 1.5 . . . 3.5

- i f

(

BRAKES


al 318 ib) 318 iA

al 533 ib) 533 iAcl 535 id)535 iAel M5

al 733 ib l733 iAcl 735 id) 735 iAel E32

a) 325 ebl 325 eAclM3

al 528 eb) 528 eA

d) 524 tdA

a) 633 CSibl633 CS|Acl 635 CSidl635 CSiAelM6

34 21 ,., Rear Wheel Brakes (Discsl

Brake pads(always use same type on ona axlel

Type

Min. pad thickness mm (in.l

Textar T 297(w. Politex)c) Jurid 238

T 260 FF (with Poli tex)

el Jurid cF 23812 el Jurid S47

Machining limit (always grindboth sides of one axle) mm ( in.)

Max. thickness tolerance ofbrake surfaces

Axial runout of brake surfaces(measursd on largest diameter

mm (in.l

8.4 (0.3311c) 10.4 (0.4091

8.4 (0.331) el 10.4 (0.40e)

8 (0.3151c) 10 {0.394)

8.0 (0.3151 el 10 (0.3941

max.0.05 (0.00201

max.0.2 (0.0081

(!

Brake liners(only use brake liners ofsame type on one axle)

Type

Machining l imit(always grind both drumson one axlel

Min. liner thickness

Max. radial runout of brakesurfaces

Brake surface finish

mm {in.l

mm {in.l

mm (in.l

Rap

BRAKES

34 - 4 from 1983 modets on

al 318 ib)318 iA

a) 325 ebl 325 eAc)M3

a) 528 eb) 528 eA

dl 524 tdA

a) 533 ib l533 iAc) 535 id) 535 iAelMS

a) 633 CSib)633 CS|Ac) 635 CSid) 635 CS|Ae) M6

a) 733 ib) 733 iAc) 735 id) 735 iAel E32

34 21 ... Rear Wheel Brakes (Drumsl

Energit 551 FF

BRAKES


al 318 ib) 318 iA

al 325 eb) 325 eAcl M3

al 528 e la) 533 ib)528 eA lU) SaS in

lc) 535 id) 524 tdA ld) 535 iA

lel M5

al 633 CSib}633 CS|Acl 635 CSid) 635 CS|AelM6

al733ibl733 iAcl 735 id)735 iAelE32

34 33 ... Brake Boostel

Pressure flow regulatorwith reservoir

Max. operating pressurefor steering circuit bar (psil 130 (18491

Upper switching pressure bar (psi) 52.. .57 (740 . . .810)

Lower switching pressure bar (psil 36 . . .41 (s12 . . .5831

{

Machining limit(always machine both drumson one axlel

Max. radial runout of brakesurface

Brake surface finish

Min. liner thickness

mm (in.l

mm (in.)

R.F

mm (in.)

34 - 6 from 19g3 models on

al 318 ib) 318 iA

al 325 eb) 325 eAclM3

a) 528 ebl 528 eA

dl 524 tdA

a) 533 ib l533 iAc) 535 id) 535 iAel M5

al 633 CSib) 633 CS|Ac) 635 CSid) 635 CS|A

a) 733 ib) 733 iAc) 735 id) 735 iAelE32

34 41 ... Parking Brake

(

BRAKES


a) 318 ib) 318 iA

a) 325 ebl 325 eAcl M3

a) 528 e lal 533 ib) 528 eA lb l533 iA

lc l535idl524 tdA lul sss in

le l M 5

al 633 CSibl633 CS|Ac) 635 CSid) 635 CSaAelM6

al 733 ib l733 iAcl 735 id) 735 iAel E32

34 50 ... ABS

Also refer to Nominal Valua Microfiche

34 51 ... Hydraulic Control Unit

Reference no. 0265 200 013cl0265 200 035

0265 201 013el

i 0265201017

0265 201 009 0265 201 008el0265 201 008

Distance (Al from pulse sensor topulse wheel(without bearing playl mm (in.) 0.25 ... 0.67 (0.010 ... 0.0261

3452... Electronic Control Unit

Reference no.' 0265 103 004 0265 100 020 0265 100 021e)0265 100 032

t IL\1

Nm (ft. lbs.)

34_A1 BRAKES

Tightening Torque

Brake caliper to steering knuckle

Guide bolt 7 mm

Screw on guide bolt (alunys replacel

Wheel cylinder to brake carrier

Brake carrier to trailing arm

Brake caliper to trailing arm

Guide bolt

3 series7 series5,6 and 7-E 32 series

5,6 and 7-E 32 series

3 series

3 series

3 series

AI

Atl

3.5. . .5 (2.5 . . .3.5)4 . . .6 (3.0 . . .4.01

86.. . 110 (63 . . .79l-80 :..95 (58 ... 691110 . . . 123 (80 . . .891

30 ... 3s (22 ...2s1

31 . . .3s 122.. .251

9 . . . 10 (6.5. . .7.01

60 . . .67 (43 . . .481

60 . . .67 (43 . . .48)

30 ...35 122 ...251

i

3432.. .

34 33 ...

Brake pipe connections

Brake hose connections

Pressure reservoir to pouor flowregulator

Hydraulic line connection onbrake boostsr

Throttle valve to brake booster

Connections on powor flow regulatorfor return line from power flowregulator to oil tank

Line from power flow regulator tobrake booster

Expansion hose from power flowregulator to steering gear

533 i/A,6 and 7 sories,535 i/A, M 5

533 i/A, 6 and 7 series,535 i/A, M 5

533 a/A, 6 and 7 series,535 i/A, M 5

533 i/A,6 and 7 series,535 i/A, M 5



10 . . . 15 (7. . . 111

13.. . 16 (e. . . 12)

25 . . .35 {18 . . . 251

25 . . .35 (18 . . .251

18 {11 . . . 131

2s . . .35 (18 . . . 25)

Atl

Atl

34 - A2 BRAKES

Type I Nm (ft. lbs.l

45 . . .50 (33 . . .36)

34. A3 BRAKES


High pressure hose from power flowregulator to power steering PumP

Hydraulic (warning| switch to powerflow regulator

Brake master cylinder to hydraulicbrake booster

Brake master rylinder to brakebooster

Brake booster to pedal base

533i1A,6 and 7 series,535 i/A, M 5


533 i/A,6 and 7 series,535 a/A, M 5

'

3 series528elA,524tdlA

3 series528 elA,524tdlA

30 . . .40 (22 . . .29!

15.. . 18 (11 . . . 13)

26 . , .32 (18 . . .23r

22.. .24 {16.. . 17)24 . . .29117 . . .211

22.. .24 {16.. . 17}22.. .24 {16.. . 17}

\

18

35 PEDALS

Model Series: ,5'

Page

Adjusting distance - brake pedal . . 35' 1 35'2 35 '3Adjustingdistance-clutchpedal 1 -2 -3Adjust ingdisunce-acceleratorpedal '1 -2 -3Side spacing control distances for pedals ' la - 2a ' 3a

,6'

Page

'3'

Page

'7 ' ,E23 ' ,7 ' ,E32

Page Page

35.4 35 - 5-4 -5-4 -5

35 213141

/ ''e

Control distance A

Control distance B

Gontroldistance A

Control distance B

Controldistance C

Lubricant for bearings

ModelSer ies3-E30

a) Manualsb) Automatics

mm (in.l 235+ 10 p.ZSZ+ 0.394;

mm (in.) 5+1 (0.197+0.0391

mm (in.l 34.5 (1.3581

mm (in.l 253+ 11 (g.SOt + 0.4331

mm (in.) 35 (1.3781

Renocal FN 745

35 21 ... Brake Pedal

35 41 ... Clutch Pedal

35 41 ... Accelerator Pedal

I

Distance from tunnel to brakepedal (F or Gl

Distance from clutch pedal tobrake pedal (Hl

Distance from brake pedal toaccelerator pedal (J or Kl


mm (in.l

mm (in.) 50 (1.e68)

mm (in.l

a l132t 5(5.197t 0.197)b) 1r$4 t 5 (5.669 t 0.197)

:

al 50 (1.9681bl62 12.4411

Renocal FN 745 from Fuchs in Mannheim

'3'Series - E 30

al ManualTransmissionb) Automatic Transmission

Control Distances for Accelerator Pedal Side Spacing (Figure 28 35 0041

g

ModelSer iesS-828

al Manualsb) Automatics


Zg1+ 10 (g.Oge + 0.394;Controldistance A mm (in. l

mm (in. lControldistance B


Controldisunce A mm ( in. l

Controldistance B mm (in.l


Controldistance C


mm (in. l

5+1 (0.197+0.0391

34.5 (1.358)

2s3 + !ts.sori8:?l8t

31 11.2201

'5 'Series - E 28

a) Manual Transmissionb) Automatic Transmission

Control Distances for Accelerator Pedal Side Spacing (Figure 28 35 0041

Distance from tunnel to brakepedal (F or G)

Distance from clutch pedal tobrake pedal (H)

Distance from brake pedal toaccelerator pedal (J or Kl


mm (in.)

mm (in.l 50 (1.9681

mm ( in. l

al 1431 5 (5.630 1 0.1971bl156r5(6.142 10.1971

a) 63 (2.4801b) 71 (2.7e5)

Renocal FN 745 from Fuchs in Mannheim

Gontrol distanca A

Control distance B

Gontrol distance A

Controldistance B

Control distance C, D, E mm (in.)

Lubricant for baarings

Model Series 6

al Manualsb) Automatics

mm (in.l 251 ...261 1s.882... 10.276)

mm (in.l s+1(o. tg7+0.0391

mm ( in.) 34.5 (1.3581

mm (in.l 271 . . .282 (10.669.. . 11.102)

a) 46 (1.811)bl 51 (2.0081

Renocal FN 20




'6 'Ser ies -E24

al Manual Transmissionbl AutomatacTransmission

Side Spacing Control Distances of Pedals lFigure 28 35 0041

Distance F or Gfrom tunnel to brake padal mm (in.) 143r5(5.630r0.197!

156 15 (6.142 t 0.1971

clutch and brake pedals mm (in.l

of brake and accelerator pedals mm (in.) 63 (2.480)71 l2.7s5l

Lubricant for bearings Renocal FN 745 from Fuchs in Mannheim

PEDALS

35-4

'7'Series - E 23

al ManualTransmissionbl AutomaticTransmission


Control distance A mm (in.) 251+9(9.882+0.3541

Control distance B mm (in.l 5+1(0.197+0.0391


Control distance A mm {in.l 34.5 (1.3581

Control distance B mm (in.l 26818 (1o.ssl 18:698rControl distance D (clutch switchl mm (in.l 5+1(0.197+0.039)


Control distances C, D, E mm (in.) a) 47 (1.850)b) 51 (2.008)

Lubricant for bearings Renocal FN 20

u

PEDALS

35-5

'7 'Series -E32

a) Manual Transmissionb) AutomaticTransmission


Control distance A mm (in.l 245 + 10 {9.646 + 0.3941

Control distance B mm (in.) 6 - 0.s {0.236 - 0.020}


Control distance B mm {in.} 265 + 10 (10.433 + 0.3941


Control distance C mm (in.l 40 (1.5751

Lubricant for bearingp Renocal FN 745 from Fuchs in Mannheim

35_A1 PEDALS

Tightening Torque

CY

Nm (ft. lus.l

Atl

E 21, E 12, E 24 until 5.82E 28, E 30, E 24 since 5.82,E32E23

E 12, E 24 until 5.82E 28, E 24 since 5.82, E 23,E32

22 (16l

27 l1e.5l

27 (19.5)

27 (1e.5)

6 (4.3)

36 (261

22116l30l22l

36 (261

22 n6l

Pedal base to body

Nut on shaft

Brake Pedal

Locknut on piston rod

Nut on shaft

Clutch Pedal

Locknuts on piston rod and spring

Piston rod shaft bolt

19

36 101112

WHEELS AND TIRES

Page

Wheels . .36-1Wheel r ims. -2Tires . - 2

'7 'E32

Page

36-3-4-4

36-A1 WHEELSANDTIRES

Tightening Torque Nm (ft. rbs.l

100 r 10 (72t71

/$t (t

WHEELS AND TIRES


alb)cld)

318 i318 iA325 e325 eA

al325 eb) 325 eA

albl

dl

528 e528 eA

524tdA

a)b)c)d)

533 i533 iA535 i535 iA

a)b)c)d)

633 CSi633 CS|A635 CSi635 CS|A

a)blc)d)

733 i733 iA735 i735 iA

2A tn l l l l l 'aal

(tira and wheel riml mm (in.l I 1.5 (0.05e1

Max. axial runout(tire and wheel rim) mm (in.l 1.5 (0.0591

Max. dynamic imbalanceper wheel gcm

Max. permissible imbalanceper side grams

One balance weight forimbalance up to 60 gr. andtwo balance weights forimbalance above 60 gr.

180

{

WHEELS AND TIRES


318 i318 iA325 e325 eA

a) 325 eb) 325 eA

528e528 eA

524 tdA

533 4533 iA535 i535 4A

633 CSi633 CS|A635 CSi635 CSiA

733 i733 iA735 i735 iA

36 11 ... Wheel Rims

See BMW Service Information Bulletinsfor equipment deviating from standardspecif ications.

Type

Wheel rim offset

Radialrim runout

mm (in.)

mm (in. l

Axialrim runout mm (in.l

36 12 ... Tires

Type

6Jx14alu 6Jx14alu 6Jx14alu

165 TR 390a,b)6112tx14 6112J x 14 alu

195/60 HR 14195/60 HR 14 195170 HR 14

see Service lnformation of Gr. 00

I

WHEELS AND TIRES

36-3

730-E32 735-E32

36 10 ... Wheels

Max. radial wheel runout{t ire on riml mm (in. l 2.0 (0.079) 1.3 (0.051)

Max. axial wheel runout(tire on riml mm (in.l 2.0 {0.079} 1.3 (0.0511

Max. dynamic imbalanceper wheel gcm 180

Max. imbalance per side grams 90

Number of balance weights forup to 60 grams of imbalance 1

more than 60 grams ofimbalance 2

f '

WHEELS AND TIRES

36-4

730 - E32', 735-E32

36 11 ... Whed Rims

Refer to BMW brochure on possibleconversions and Service Informationbulletins for deviations fromstandard equipment.

Only use samo type wheel rims onone Gar.

Designation 6112J x 15 H2 7Jx15H2

Wheel rim offset mm (in.l 2010.7871

Max. radial rim runout mm (in.l 1.0 {0.03e} 0.3 (0.012"1

Max. axial rim runout mm (in.l 1.0 (0.03e1 0.3 (0.012")

36 12... Tires

Designation 205/65 VR 15 225160 VR 15

Approved tire makes see Service Information of Gr. 36

qt,.

19

37 INTEGRATED SUSPENSION SYSTEMS

'7' ,E32

Page

00 General informat ion . . . . .37-112 Car ride levels . - 112 Spring struts . - 221 Pressure reservoirs - 231 Hydraulic switch (low pressure) . . - z31 Hydraulic switch (high pressure) - 3

61

t

INTEGBATED SUSPENSION SYSTEMS(Ride Control)

37-1

'7 'Ser ies -E3?

37 00 ... Ride Control in General

Oil grade Castrol LHM, Pentosin CHF 45, Total LHM, Veedol LHM

Oilvolume ltr. (pts.) 1.s (3.2)

37 12... Gar Ride Level

Height {lower edge of wheel houseto rim flange at center of wheel)with car loaded down to normalposition (see page 32 - 100) mm (in.l 522 ! 10 (20.551 r 0.394)

With TRX 415 t ires and carloaded down to normalposition (see page 32 - 70U mm (in.) 534 r 10 (21.023 t 0.394)

Max. difference in deviation fromnominal value among all wheels mm (in.) 10 (0.3e4)

Remaining rod length(basic adjustment) mm (in.) 275110.827ti

s7 -- A 1 TNTEGRATED SUSPENSION SYSr cMS(Ride Control)

Tightening Torquel Nm (f t . lbs.)

37 13.. .All pressure line connections

61 31 . . .Hydraulic switch on branch

Hydraulic switch on hydrauliccontrol unit

Solenoid valve on hydrauliccontrol unit

20 . . . 30 {14.5 . . . 21.5)

25.. .30 (18.. .21.s}

50 . . .60 (37 . . .43)

I NTEG RATED SUSPENSION SYSTEMS(Ride Controll

37 -2

'7 'Series - E 32

37 12... Spring Strut Shock Absorbers

Only install shock absorbers of same BMWnumber (stamped on absorber housing) onone axle.

Shock absorber test values see Service Information of Group 37

37 21 .., Pressure Reservoirs

Charging pressure at 20o C (680 F) bar (psi) 23 10.5 1327 ! 7l

tl 31 ... Hydraulic Switch (Low Pressure)

Switching point bar (psi) so*_rtazt +_l$t

INTEG RATED SUSPENSION SYSTEMS(Ride Control)

'7 'Ser ies -E32

61 31 .,. Hydraulic Switch (High Pressure)

Switching point bar (psi) 110 t 12 11564 t 171!/

41

41

BODY

Adhesives, sealing compounds

t'v

Page

..41 -1

All Models

41 ... Adhesives, Sealing Compounds

Weatherstrips on doors, trunk lid IHWB profile rubber cement I et ZZ 9 400 bOO / OlSHWB fast-drying cement I Bt zzg 4oo gz7

Seam sealingHWB bodv seating compound - btack I el zz 9 400 / 014 81 229 407 118 8122I407 313HWB bodv seating compound - tight I at zz g 4oo I 247 81 22 g 4O7 117 81 22 I 407 389

Metal screwed connections IHWB seating tape I e't zz9 400 019 81 229 407 390

81 22 I 400 248

Permanent undercoating I3 M Body Plast (anti-drumming effect) |HWB No. I at zz9 4oo 399

81 22 I 407 001

Zinc dust paint IHWB No. I at zz I 400 7s2

Thermal insulating paste IHWB No. I et zz I 407 038

HWB: A Division of the BMW AG

oEN(gF

o.tO

:0vcIocttr

FOzc,LU Ett .E-B(E

5so;r r r q,

'^( l 'f:l gv9dl

I

lo1f,,

BODY EOUIPMENT

-2

'7 'Ser ies -E32

51 ... Adhesives, Sealing Compounds HWB Number

CarpetsHWB universal cement 8122 9 400 017

Seals on doors and trunk l idHWB profile rubber cementHWB fast-drying cement

81 22 I 400 s00 / 01581 22 9 400 327 I 81 22s 407 143

Seam sealing (to be painted over)HWB body seal ing compound-blackHWB body sealing compound-lightHWB body sealing compound-white

81229 400 /22781 22I400 / 01481 22 I 400 / 348

Metal screwed connectionsHWB sealing tape 81 229 400 248

Undercoating3M Body Plast (anti-drumming effect) 81 22 I 400 399

Zinc dust paint for bores and weldedseams to prevent corrosion 81 22 I 400 792

Window cement HWB repair kit

Silicone spray for lubrication of doorlocks, hinges, rubber and plastic parts 81 22 9 407 004

. . .A 1 BODY EOUIPMENT


51 1l . . . Front Bumper

Bracket to bumper

Bracket to engine carrier

- Bolts- Nuts- Bolts

Bumper to side panel

51 12 ... Rear Bumper

Bracket to bumper

Bracket to body

M10x75M10M10

3, 5, 6, 7 - E 23 seriesE32

3,3-E30,5and6ser ies5-E23ser ies7 series7 seriesE32

3 and 5 series3-E30and5-E23ser ies

3, 5, 6,7 - E 23 ser iesE32

3,5,5 -E28,6ser ies7-E23ser ies3-E30E32

3, 5, 6 series3-E30,5-E2Sser ies

22.. .25 (16.. . 18)73 (53)

22.. .25 (16.. . 18)43 (31)30 ... 35 122 ...25l,43 (31)42 (30)

10 . . . 12 (7 . . . 8.5)6 . . . I (4.5 . . .6.5)

22.. .25 (16.. . 18)73 (53)

22.. .25 (16.. . 18)43 . . .48 (31 . . .34)I . . . I (6.0 . . .6.5)e (6.5)

10 . . . 12 (7.0 . . . 8.5)6 . . . e (4.5 . . .6.5)

J

54 -A 1 SUN ROOF /TOP

Tightening TorqueNm (f t . tbs.)

Motor to cassette

Rail to cassette2.8 .2.01

1.8 (1.3)

2.8 (2.0)

3.5 (2.5)

f

'3

GENERAL CAR ELECTRICAL SYSTEM


318 i 325 e 524 td 528 e533 i535 i

633 CSi635 CSi

733,735 i

61 31 ... Switches

Temperature switch 91oC (195oF)

Switching on temperature oC (of ) 89 . . . e3 (192 . . . 19e)

Switching off temperature oC (of ) 82.. .86 (180 . . . 1871

Temperature switch 99oC (21OoF)

Switching on temperature oC (of ) 97.. . 101 1207 . . .2141

Switching off temperature oC (oF) e0 . . . 94 (194 . . . 201)

A q

20

61 GENERAL CAR ELECTRICAL SYSTEM

E 23, E 24, E 29, E 30 Page

Battery .61 - lSwitches - 2Washing f luid pump .3


M3,M5,M6, '7 'E32 Page

Battery . . 61 .10Switches - 10Washing f luid pump - 1l

61

61 203166

61 203166

r



318 i 325 e 524 td 528 e533 i535 i

633 CSi635 CSi

733 i735 i

61 31 ... Switches

Brake pad wear sensors

Warning position with padthickness

min. mm ( in.) 1.5 (0.05e)

max. mm ( in.) 3.s (0.138)

61 66 ... Washer Pump

Min. del ivery pressure bar (psi) 1.5 (21)


6'.t - 10

735-E32

Rated voltage V

Capacity Ah

61 31 ... Switches

0o C (32o Fl temperature switchand oil pressure switch

Additional fan temp. switchDouble temperature switchSwitching-on temperature

stage I oc (or) 82 13(180 r 5)

Stage l l

Switch i ng-off temperatu reStage I

oc (or)

oc (or)

oc (or)Stage l l

9to C (1960 F) switchSwitching-on temp.Switching-off temp.

oc (or)oc (or)

99o c (210o Fl switchSwitching-on temp.Switching-off temp.

oc (orloc (or)

see Group 12

91 r3(19615)

91 t3(196r 5)

99r3(210r51

84r3(18315)75 r3 f i6715)

92t3(198t5184 t3 (1831 5)

9r t2 f l961 4)84 r2 083! 4l

99 t2 (210 r4)92 t2 (r98r 2l


61 - 11

M3 M5 M6 735-E32

61 31 ... Switches

Brake pad wear sensor warningposition with residual padthickness of

at least mm ( in.) 2.0 (0.07e1

maximum mm ( in.) 4.1 (0.161)

61 66 ... Washing Fluid Pump

Min. delivery pressure bar (psi) 1.5 (21)

61 _ A 1 GENERAL CAR ELECTRICAL SYSTEM


Temperature switch 0o C (32o F)

Temperature switch 91o C (195() Fl

Temperature switch 99o c (2100 Fl

Oil pressure switch

Temperature sensor

Backup light switch

max.30 (221

max. 15 (11)

max. 15 (11)

max.50 (36)

max.30 (22)

max.20 (14)

21

INSTRUMENTS

Codingpfug. . . . .62-1 -10Instrumentcluster .3 - l lSpeedometer .4 .12Tachometer. . . . -S -13Economy control .6

M3,M5,M6, '7 'E32

Page

62 11

1213

. . ; r

i'i.diii

INSTRUMENTS

62-1

318 4 325 e 524 td a) 528 eb) 533 ic) 535 i

al 633 CSib) 635 CSi

al 733 ibl 735 i

6211 ... Coding Plug

Instrument carrier untal 1985/1986

BMW No. 6211 -1372 265.9

6211 -1375 716.9

62 11 -1 373 086.9

a)6211-1 375 990.9

b)62 11 -1 370 248.9

c)6211-1 376 629.9

a)6211-1 370 247.9

b)62 11 -r 376 631.9

a)6211-1 370 247.9

bl62 11 -1 376 631.9

Code 03 09 13 al 18b) 07c) 19

a) 06b) 20

al o6bl 20

Color yellow/green a) green/greenblbrwn/yellowc) green/red

a) brown/brownb) red/white

a) brown/brwrb) red/white

INSTRUMENTS

62-2

E30 E23lE24lE28

62 11 ... Coding Plug

Cross reference of code numbers and corresponding part numbers (BMW Parts Microfiche)

Instrument carrier since 1985/1986 (identification: only 1 red LED in Service Indicator)

Code Number

06

BMW Part Number

62.11.1 377 368.9

BMW Part Number

08 62.11-1377 363.9

11 62.11-1 377 662.9

12 62.11-1377 663.9

13 62.11-1377 664.9

14 62.11-1 377 665.9

,.i.,;l

INSTRUMENTS 318 i

f rom model 1983 on

633 CSi635 CSi

6211 . . . Instrument Cluster

Temperature gauge

Gauge val ue/comparativeresistance/needle def lection

oc (or)40 (105)61 11421

115 (249)1281262l.

2871272518

Fuel gauge

Gauge value/comparativeresistance/needle def lection

R114112314F

71.759.225.713.03,2

0195670.582.5

Gauge deviat ion l imit(with 20o C/68o F ambienttemperature and 14 V testvol tagel

Temperature transmitter see Group 12 62 . . .

t 30 36',

oc (or)40 (105)60 (140)66 (151)70 (158)B0 (176)92 {198}

10212161115 (24s1128 (2621

287132112966849362518

08

13172945617890

R114112314F

71.755.230.112.73.2

011426982

' .1

' ' .1:,.;Edll

INSTRUMENTS


31B a 325 e 524 trl 528 e533 i535 i

633 CSi635 CSi

733 i735,

-6t<5K->b_v.

6212.. . Speedometer

Constant W (pulses/mile) 7849 7522 7313

No. of pulse spider teeth 9

F requenzy/speed comparison

40

50

60

70

BO

90

100

110

120

130

140

87' ;

rcsto%E..:.1\LZ5$3'fia

::,:#f;1218

MpH I n '

40t84

50 | ,ouI

60 |

12s

70 |

raoB0

| 167

e0 |

188

100 |

20e

110 |

230

12o |

251

130 |

272

140 |

2e3

1s0 |

313

160 | 334

MpH II

40 1I

50 160

70

80

90

100

110

120

130

140

150

160

nl4+vF

taw56l lcp) l7s( rtol I)o |l 1;r.rt

\

B1

102

122

142

163

183

203

224

244

264

284

305

325

Gauge deviation l imit(with 20o c / 680 F ambient

temperature and 14 V testing

voltage ): ,

of r l isplayed range value

I

)

INSTRUMENTS


318 i 325 e 524 td

- ' i

528 e533 i535 i

633 CSi635 CSi

733 i735 4

62 13. . . Revolution Counter

Gauge deviat ion l imit (with20oC/680Fambienttem-perature and 14 V test ingvoltage) !2 o/o ol displayed range value

rpm

Displayed value / 1000Frequenzy 2000

30004000500060007000

Hz

33

Hz

50

Hz

100

Hz

5067 100 200 100

100 150 300 150133 200 400 200167 250 500 250200 300 600 300233 350 350

i

: . , ! : r1

'1't&l'

633 CSi635 CSi

528 e533 i535 i

INSTRUMENTS


62 13 ,.. Economy Control

Displayed value

Consumption signal

Gauge deviat ion l imit

INSTRUMENTS I M 3

62-10

M5 M6 735-E32a) Standardb) Replacement

t

6211 ... Coding Plug

BMW No. 62 111 381 699.9

6211 1 377 664.9 a) 62 111 379 627.9bl62 111 379 628.9

Code 12 13 114

INSTRUMENTS

62-11

M3 M5 M6 735-E32

62 11 ... lnstrument Cluster

Temperature gageGage value/comparativeresistance/needle def lection

oc (oF) / ohms40 (1051/28760 (r401/13266 f l5r) /1t270 fi58)/ 9680 076)/ 6892 (198)/ 49

r02 (216)/ 36r15l24gll 25128 (262t,1 18

og (oFl / ohms40 11041 | 2874s.5 (1141 124065 (14e) / 11692 (1e8) / 47.7

115.5 12401 I 24.4126 |.2591 I 19128 12621 I 18.1

oc (or) / ohmst0 ( 501/917755 (r421/144870 fl58)/ 85885 (185)/ 617

100 (212)/ 323rr5 (239)/ 2191241255l,1 112

Fuel gageGage value/comparativeresistance/needle def lection

o/o

R114112314F

/ Ohms/ 58.5143.4126.8t -I 3.2

o/o

R114112314F

/ Ohms171.7154.2125.7/ 13.8| 3.2

see Gr. 16

Gage deviation limit(with 20o C/68o F ambienttemperature and 14 V testvoltage) + 30 36',

Temperature transmitter see 12 62 . . . in Group 12

.''rffi

INSTRUMENTS

Constant W (pulses/mile)

No. of pulse spider teeth

Frequency / Speed Comparison mph lHz I mph / Hz40871+08360 130 I 0o 12580 173 | s0 166

loo 216 | too 20812O 260 | tzo zso140 303 | tco 291160 346 | r0o 332

mph / Hz40 8160 12280 162

100 203120 243140 284160 324

I

INSTRUMENTS

62-13

M3 M5 M6 '7' , -E32

6213... Tachometer

Gage deviation limit (wittr 20o Cor 680 F ambient temperatureand 14 V testing voltage) ! 2o/o of displayed range value

Displayed value / frequency RPM1000200030004000500060007000

Hz3367

100133167200233

Hz50

100150200250300350

I

21

63 LIGHTS

'7 '832

Page

63 121314212631

Headl ights . .63- l .10Frontturnsignals -1 -10Side marker lights - 1Tai l l ightassembly -1 .11Licenseplatel ights - l -11fnter ior l ights. -2 -12

LIGHTS

from 1983 models on

633 CSi635 CSiM6

6312... Headlights

cE 4000 l12v 137.s w)Low beam lamp

High beam lamp

63 13 ... Front Turn Signals

Light bulb Type

63 14 . . . Side Marker Lights

Light bulb Type

63 21 ... Tail Light Assembly

Light bulb - stop l ight Type

Light bulb - turn signal Type

Light bulb - backup l ight Type

Light bulb - tai l l ight Type

63 26 ... License Plate Laghts

Light bulb Type

cE H 4001 l12V 137.5 W)

P 25-2 (12 V - zllswl

HL12V4WT 814 - 12V 4W

P 25-1 - 12V - 21W

P 25-1 - 12V - 21W

P25-1 -12V-21 W

G12V5W

L12V5W

633 CSi635 CSiM6

528 e533 i535 i


63 31 ... Interior Lights

w5/1 .2-12V1.2WControl uni t l ight TYPe

Instrument l ight TyPe

Ind. lamps in instr . c luster TYPe

Battery charge indicator lamp Type

Inside lamp TYPe

Trunk l ight Type

Glove box l ight Type

Engine compartment l ight TYPe

Light for heater controls Type

w10/3-12V3W

w5/1 .2-12V1.2W

w10/3-12V3W

K12V10W

L12V5W

HL12V4W

L12V5W

w 5/1 .2-12 V 1.2 W

w5/1 .2-12V1.2W

w5/1 .2-12V1.2W

w5/1 .2-12V1.2W

Light in main l ight switch Type

Light in fog l ight switch Type

Digital c lock l ight Type

)

LIGHTS

63-10

'7 'Ser ies -E32

63 12... Headlights

Light bulb for low beams Type 9006

Light bulb for high beams Type 9005

Light bulb for parking lights Type w10/512V5W

63 13 .,. Front Turn Signals

Lisht bulb Type IP25-1-12V21 W

LIGHTS

63-11

'7 'Ser ies - E 32

63 21 ... Tail Light Assembly

Light bulb for stop light Type P25-1-12V21W

Light bulb for turn signal Type P25-1-12 V21 W

Light bulb for tai l l ight Type G12V5W

Light bulb for rear fog light Type P25-1-12V21W

Light bulb for backup light Type P25-1-12V21W

62 26 ... License Plate Lights

Light bulb Type c11-12V5W

Reading lamp

Front inside lamp

Rear inside lamp

Trunk l ight

Glove box light

Engine compartment light

Symbol l ight bulbs

LCD module display panel

Footwell entrance lights

'7'Series - E 32

Type

Type Sofite 12 V 15 W

Type K.12V5W

Type K-12V10W

Type c11-12V5W

Type L12V5W

Type w 5/1 .212V 1.2 W

Type w 5/1 .212V 1.2W

Type c11 -12V5W

63 31 ... Interior Lights

Halogen 12 V 10 W

22

64 HEATER AND AIR CONDITIONER

page

Watervalve. . .64---Temperature sensor - heaterTemperature sensor - passenger compartment . . . . .Temperature sensor .- intake air . . .Temperature selection contro!Temperature control switchControl unit .Safety switchGeneral informationEvaporator sensorExpansion valve .CompressorDrierSafety switch

123467II

101112131415

64 11111111111111

64 3364 5064 51

5164 5264 5361 31

)

23

64

64

HEATER AND AIR CONDITIONER

Heater

'7 ' ,E32

Page

1111111111

Control unit . 64 - 401Temperaturesensor - passengercompartment... -402Temperature sensor - outside - 403Temperature sensor - heater - 404Blower motor - 405

Air Conditioner Page

General information . 64 - 601General information - 602Evaporator sensor - 603Expansionvalve. -604Safety switch (high pressure pressostat) . . . - 605Safety switch (low pressure pressostat) - 606Safety switch (medium pressure pressostat) - 607

64 50505151535353


f rom 1983 models on

64 11 . . . Water Valve

a) 318 ib)318 iAM3

a) 325 eb) 325 eA

a) 528 eb) 528 eA

a) 533 ib) 533 iAM5

a) 733 ib)735 iA

1 370 812 1 373 191

a) 633 CSib)633 CSiAM6

open without current open without current



a) 318 ib)318 iAM3

a) 325 eb) 325 eA

a) 528 eb) 528 eA

a) 533 ib)s33 iAM5

a) 633 CSib)633 CS|AM6

a) 733 ib) 735 iA

64 11 ... Heater Temperature Sensor

Code no. 1 368 649

Reslstance depending onambient temperature oc (oF)a k-ohm 20 F 4) e 84.39.. . 109.61

10 (+ 14) = 48.58.. . 62.080 (+ 32!. .28.89.. . 36.40

20 (+ 68) ^ 11.13.. . 13.83251+ 771 2 9.00.. . 11.0060 (+ 140) a 2.19.. . 2.78

100 (+ 2121 2 0.58.. . O.77

)



a) 318 ib)318 iAM3

a) 325 ebl 325 eA

al 528 eb) 528 eA

a) 533 ib)533 iAM5

a) 633 CSibl633 CSIAM6

a) 733 ib)735 iA

64 11 ... Temperature Sensor - Passenger Con

code no. I(with air condit ioner) I

tpartment

1 369 B2B

Resistance between term. 1 and 3at 25o C (77o F) ohm 33 r 8.5

Resistance between term. 2 and 3depending on ambient temPerature

0o C ( 3Zo Fl k-ohm 32.4 ...37.7

10o c ( 50o F) k-ohm ls .4. . .22.1

lbo C ( bgo F) k-ohm 15.1 ... 17.2 2.8 . . .3.1

2Oo C ( 680 F) k-ohm 12.0 . . . 13.3 2.48.. .2.68

zso c | 77o Fl k-ohm 9.5. . . 10.5 2.13 . . .2.3

30o C ( 860 F) k-ohm 7.5 . . 8.4 1.82.. . 1.98

35o C ( 95o F) k-ohm 1.50.. . 1.73

4Oo C (1040 F) k-ohm 4.7 . . .5.4

4bo C (1130 F) k-ohm

a) 733 ib)735 iA


a) 533 ib)533 iAM5

a) 528 eb) 528 eA

a) 325 eb) 325 eA

a) 318 ib)318 iAM3



64 11 ... Intake Air Temperature Sensor

Code no.

Resistance between term. 2 and 3depending on ambient temp.- 3oo c (- 22o F) k-ohm

-200c(- 40F) k-ohm

_ 1oo c (+ 14o F) k-ohm

00 c (+ 320 Fl k-ohm

loo C (+ 50o F) k-ohm

150 C (+ 590 F) k-ohm

20o c (+ 680 F) k-ohm

2So c (+ 77o F) k-ohm

30o c (+ 860 F) k-ohm

1.48 . . . 1.6

1.30 . . . 1.45

1.11 . . . 1.25

0.90.. . 1.2

0.70 . . .0.8

0.62 . . .0.7

0.55 . . .0.62

0.48 . . .0.53

0.41 . . .0.46


from 1983 models on

64 11 ... Complete Sensor Set

Temperature AmbientSelection Control TemPerature

a) 318 ib}318 iAM3

a) 533 ib) s33 iAM5

o6 op15 59

og op

22 72 16

22 72 18

22 72 20

22 72 22

22 72 24

22 72 26

22 72 28

61

75

82


K.OHMS< 1.5

4.64 . . .5.00

4.46 . . .4.77

4.30 . . .4.59

4.14 . . .4.42

4.O1 . . .4.25

3.86 . . .4.08

3.72.. .3.94



a) 318 ib)318 iAM3

a) 325 eb) 325 eA

a) 528 eb) 528 eA

a) 533 ib)533 iAM5


a) 733 ib)735 iA

64 11 ... Temperature Selection Control

Adjusting value22o c l72o Fl ohm 1035r5%

Testing valuelso c (59o F) ohm 350 . . .473

1537 . . . 165129o c (84o F) ohm


from 1983 models on

64 11 ... Temperature Control Switch

a) 318 ib)318 iAM3

al 528 eb) 528 eA

a) 533 ib)533 iAM5

a) 733 ib)735 iA

a) 325 eb) 325 eA

al 633 CSib)633 CS|AM6

Code no. 1 369 428

Switch i ng-on temperature oc (or)

oc (or)

6 . . .8(43 . . .46)

35 . . . 5.5(e5 . . .42)

Switch i ng-of f temperatu re o.. .+2(32 ... 36)



a) 318 ib)318 iAM3

a) 325 eb) 325 eA

a) 528 eb) 528 eA

a) 533 ib)533 iAM5


a) 733 ib)735 iA

64 11 ... Control Unit

Code no. 1 373 189 1 368 451

Operating voltage V I . . . 15 9.. . 15

Adjusting range oC (oF) 14.5 t 3 .. . 55.5 t 4.5 (58 + 5 .. . 132 r 8)

Timing for water valve sec. 33 r 0.7


64 * I f rom 1983 models on

a) 318 ib)318 iAM3

al 325 eb) 325 eA

al 528 eb) 528 eA

a) 533 ib) s33 iAM5


a) 733 ib)735 iA

64 33 ... Safety Switch (Low Pressure Pressostat)

Testing voltage V 13 r 0.26 13 r 0.26

Switch ing-off pressu re(with dropping pressure) Uar (psi) 1.72 . . .2.22

(24.46 ... 3t.56)1.72.. .2.22{.24.46...31.58)

Switching-on pressure(with r is ing pressure) bar (psi) 2.0 . . .2.4

(28.45 ... 34.14)2.O . . .2.4(28.45 ... 34.14)

Operat ing pressure bar (psi) 0.034 . . .35(0.48 . . .498)

0.034 . . .35(0.48 . . .4e8)

a) 733 ab) 735 iA


a) 533 ib)533 iAM5

a) 528 eb) 528 eA

a) 325 eb) 325 eA

a) 318 ib)318 iAM3



64 50 ... General Information

Ref rigerant (difluordichlormethane)HWB No.

Boil ing point with 1 bar (14 Ot,) oa (or)pressure

Refrigerant volume gr.

Refrigerant charging Pressure

Refrigerating machine oilHWB No.

Frigen 12CF 2 Cl?81229 407 035

- 2e.8l-221

approx. 1300

approx.4.5. . .8.0 (64 . . . 114)

81 22 I 407 028

b)735 iAa) 633 CSib)633 CSiAM6

a) 533 ib)533 iAM5

a) 528 eb) 528 eA

a) 318 ib)318 iAM3

a) 325 eb) 325 eA



64 50 ... General Information

Refrigerant (difluordichlormethane)HWB No.

Boil ing point with 1 bar (14 Ot,) oa (orlpressure

Refrigerant volume gr.

Refrigerant charging pressure bar (psi)

Ref r igerat ing machine oi lHWB No.

Frigen 12 CF 2 Clz81229 407 035

- 2s.8l-221

approx. 1300

81229 407 028

-t)


64 - 1 1 lrom 1983 models on

a) 318 ib)318 iAM3

al 325 eb) 325 eA

a) 528 eb) 528 eA

a) 533 ib)s33 iAM5


al 733 ib)735 iA

64 51 ... Evaporator Sensor

Code no. 1 368 638 ll

Resistance depending ontemperature

bo c (+ z3o Fl k-ohm . 11.4. . . 11.9

oo c {+ 32o F) k-ohm^ 8.4. . . 9.2

so c (+ 4to F) k-ohm 6.8 ... 7.2

1oo c (+ 5oo F) k-ohm a 5.3. . . 5.6

15o c {+ 59o F} k-ohm 4 4.2. . . 4.5

2oo c (+ 680 F) k-ohm^ 3.3. . . 3.6

zso c f t77o Fl k-ohm e 2.6. . . 2.9

3oo c (+ goo r) k-ohm ^ 2.1 . . . 2.3

35o c (+ gso F) k-ohm ^ 1.7 . . . 1.9



a) 318 ib)318 iAM3

a) 325 eb) 325 eA

a) 528 eb) 528 eA

a) 533 ib)533 iAM5

a) 633 CSib)633 CSaAM6

a) 733 ib}735 iA

64 51 ... Expansion Valve

Code no. 1 354 379 1 368 581

Input pressure bar (psi) 14 (1ee) 14 (1e9) 14 ( r9e)

Output pressure bar {psi} 1.8 (26) 1.8 (26) 1.8 (26)

Leak test with leak detector and air conditioner switched off

)


IOQ? mndolc

a) 318 ib)318 iAM3

a) 325 eb) 325 eA

a) 528 eb) 528 eA

a) 533 ib}533 iAM5

a) 633 CSib) 633 CS|AM6

al 733 ib) 735 iA

Code no. I 1 370 081

600 . . .8000

I

1 370 oB1 I t goz ass

Speed range rpm 600 ... 8000 600 ... 8000

Power required at 2800 rPm KW approx.4 approx.4 approx, 4

Oil gradeHWB No.

Oi l volume cc

81229 407 028

approx. 170

a) 733 ib}735 iA


a) 528 eb) 528 eA

a) 533 ib)533 iAM5

a) 325 eb) 325 eA

a) 318 ib)318 iAM3



Installed position

Safety fuse og {oF) 114 . . .120 (237 . . .248l



61 31 ... Safety Switch (High Pressure Pressostat)

Testing voltage

Switch i ng-of f pressure(with rising pressure) bar (psi l

Switching-on pressure(with dropping pressure) bar (psi)

Permissible operating pressure bar (psi)

a) 318 ib)s18 iAM3

a) 528 eb) 528 eA

a) 533 ib)533 iAM5

al 733 ib)735 iA

13 t 0.26

20.0 .. . 22.5 1284... 320)

20.o ... 22.5 |.284... 320)

a) 325 eb) 325 eA


HEATER AND AIR CONDITIONER '7'Ser ies-E32

64 - 401

64 11 . . . Controt uni t ( tHRl

Code no. 1 374 389

Operating voltage I . . . 15

64 11 . . . Controt Uni t ( IHKA)

Code no.

Operating voltage


(Heater)

64 - 403

64 11 ... Outside Temperature Sensor

Resistance depending on temperature

'7 'Ser ies -E32

1 378 850

K.OHMS

-25-20-10

010202530405060708085

-13-4+143250687786

104122140r58176185

9.12 . . . 13.687.O2 ... 10.224.28 . . .5.852.69 . . .3.461.74.. .2.111.15 . . . 1.320.95.. . 1.050.76 . . .0.870.49 . . .0.600.33 . . .0.420.22 . . .0.300.15 . . .0.220.11 . . . 0.160.09 . . .0.14

t:r,;lfill


(Heater)

64 - 405

'7 'Ser ies -E32

64 11 ... Blower Motor

Code no. 1 366 910.4

Testing voltage IIA

13 t 0.26

Operating voltage I . . . 15

Power consumPtion approx.27

Speed rpm 3600 ...4000

Axial play mm ( in.) 0.1 - o.zs (0.004 - o.olo)

lHEATER AND A!R CONDITIONER

(Air Conditioner)

64 - 601

'7 'Ser ies-E32

Refrigerant Frigen 12

HWB number 81 22 I 407 035

1500 t 25

1925 !25

Refrigerant volume grams

Liquid refr igerant volume grams

Charging pressure

Ref r igeration machine oi l

Volume in compressor

6r, lpsi) I (114)

HWB No. 8122 9 407 028

200

Magnetic clutchMax. power consumption A 3.3

'7 'Ser ies -E32HEATER AND AIR CONDITIONER

(Air Condit ioner)

64 - 602

Volume of refrigeration machineoil added after replacement of

drier

evaporator

condenser

pipe

approx.40

approx. 10

,-.


(Air Condit ioner)

64 - 603

64 51 ... Evaporator Sensor

Resistance depending on temperature

'7'Series - E 32

K-OHMS

5 +23032541

10 5015 5920 6825 77

11.4. . .11.98.8 . . .9.26.8. . .7.25.3 . . .5.64.2 . . .4.53.3 . . .3.62.6. . .2.9

:' , ' , i { :,i,4iil*.

64 51 ... Expansion Valve


(Air Condit ioner)

64 - 604

Input pressure

Output pressure

Leak test with leak detectorat pressure of

1 380 506

631 (psi)

66y (psi)

uar (psil 1 . . .2 (14 . . .28)

,il$llx


(Air Condit ionerl

64 - 605

64 53 ... Safety Switch (High Pressure Pressostat)

Testing voltage

Switching-off pressure(with dropping pressure)

'7 'Ser ies -E32

611 lpsi) 30 t 1.03 (427 t 15)

bar (psi) 21.17 1 1.4 (301 r 20)

bar (psi)

Switching-on pressure(with rising pressurel

Operating pressure


(Air Conditioner)

64 - 606

'7'Series - E 32

64 53 ... Safety Switch (Low Pressure Switch)

Testing voltage


Switching-on pressure(with rising pressure)

Operating pressure

13 t 0.26

bar (psi)

bar (psil 2.0 ... 2.4 128.5... 34.0)

bar (psi) 0.034 . . . 35 {0.5 . . .500)


(Air Conditioner)

64 - 607

Testing voltage


Switching-on pressure(with rising pressure)

Operating pressure

'7'Series - E 32

bar (psi) 15 r 1.03 (213 t 15)

bar (psi) 18t1.41256!201

bar (psi) 0.034 . . .35 (0.5. . . 500)

64 53 ... Safety Switch (Medium Pressure Pressostat)

._1,

,t i idfi

b4 - A 1 HEATER AND AIR CONDITIONER

Tightening Torque Nm (f t . lbs. l

Safety switch - high pressurepressostatHWB No. 81 229 4O7 144

Safety switch - low pressurepressostatHWB No. 81 229 407 144

14 . . .20 (10 . . . 14)

33 ...39 124 ...28l.

36 . . .42 (26 . . .30)

40 . . .48 (2e . . .35)

15.. .25 (11 . . . 18)

17 . . . le (12 . . . 14)

.r;it

65 12

RADIO AND SPECIAL EOUIPMENT

Page

Radio speakers . 65 - 1Speaker balance control - 1Automatic antenna -2Shielding - 2Cruise control - 3On-board computer coding plug table - 4

22317181

.

528 e533 i535 i

733 |735 iRADIO AND SPECIAL EOUIPMENT


318 i 633 CSi635 CSi

65 12 ... Radio SPeakers

Power handl ing caPacitY W

Music handl ing caPacitY ohm 4t 10%atlkhz

6512 . . . Speaker Balance Control

40r 15%Nominal resistance R 1/R 2 ohm

Right or lef t stoP resistance ohm

65 13 . . . Sound-System

4,Bt 10%atlkhz

Speakers front

Power handl ing caPacitY

Music handl ing caPacitY

Speakers rear

Power handling caPacitY

Music handl ing caPacitY

Treble speakers

Power handl ing capacitY

Music handling caPacitY

4,0110%atlkhz

8110%atlkhz



318 i 325 e 524 td 528 e533 i53s i

633 CSi635 CSi

733 i735 i

65 22 ... Automatic Antenna

Code no. 920 506-002 1930 314-022

Operating voltage V 10.5. . . 14.5

Max. power requirement A I

65 31 . . . Shielding

Capacitor on alternatorCapacitance pF 2.2!20%

633 CSi635 CSi

528 e533 i535 i



65 22... Automatic Antenna

920 506-002 / 930 314-022

2.2 !20%

Operating voltage

Max. power requirement

65 31 . . . Shielding

Capacitor on alternatorCapacitance

A

pF

633 CSi635 CSi

65 71 ... Regulator for Electronic Cruise Control

Code no.

Operating voltage V

Pulse K1

65 71 ... Motor for Electronic Cruise Control

Code no.

TimingActivated sec.

Unactivated. (via motorl sec.

Unactivated(via clutch) sec,

Play of cable control in neutralposition with engine at operat-Ing temperature and ignitionon mm ( in. l

65 71 ... Clutch Switch

Adjusting distance mm ( in.)

1 369 772.3

10.8 . . . 14.5

1 370 159.9

1 . . . 2 (0.039 . . . 0.079)

511(0.197 10.039)

318 iRADIO AND SPECIAL EOUTPMENT

65-3 f rom modet 1983 on

528 e533 i535 i

733 i735 i



65 81 ... On-board Computer Coding Plug Table lst Generation

Vehicle Typ I BMW Number ; Code Number Color Codelst Stripe I zna Stripe 3rd Stripe

528 e 6s 81 - 1 370 237.9 o 1 - x7117 yellow green

533 i 65 81 - 1 372 933.9 o 1 - x7124 orange black green

633 CSi 65 81 - 1 372 013.9 o 1 - x7122 orange black white

733 i 65 81 - 1 368 582.9 o1-x7101 black black



65 81 ... On-board Computer Coding Plug Table 2nd Generation

Vehicle Typ Engine I BMW Number Print I Pulse NumberControl Indicator I l/M

318 i MlOB18LU 65 81 - 1 376 027.9 3 - 3TYP 7849

325 e M20B27MV 65 81 - 1 373 698.9 3 - STYP 7849

528 e M20B27MU 65 81 - 1375 814.9 5-8TYP 7522

535 a M30B34MU 65 81 - 1375 826.9 5-6TYP 7522

635 CSi M30B34MU 65 81 - 1 375 021.9 6-2TYP 7313

735 i M30B34MU 65 81 - 1 375 823.9 7_4TYP 7313

l, t - A t EOUIPMENT PARTS AND ACCESSURIES

FOR BODY

Tightening Torque

Seat BelE

Mounting bolts

Mounting bolts for sest beltheight control

Nm (f t . lbs.)

E 21,E30,E 28,E 24,E23

7 -E32

43 . . .48 (31 . . .341

24l17l

24

BODY CAVITY SEALING AND UNDERCOATING

Materials

l

BMW M6 Torque Specs

Documents

Transcript of BMW M6 Torque Specs