FUNDAMENTALS FOR THE DO-IT-YOURSELF OWNER 010-3 | warwine— * Nover work undor a ito ca” unis sly supported on jack stands that are intanded for that purpose. De not support a ear on cinder Docks, brick, or othr objects that may shit or ‘rumble une contnuusioad, Never wok ur {er acar ati supperied oni by the iting jack + Fuols highly anmabie. When working around {uot donot smoke or work near haaters or ether fe hazards. Keep an approved te exinguisher andy + Iluinate the work area adequately and satel. Use a parable sat ght or working inside or under te car A uorescent tye lat i= best be ‘cause tghes of as heat. using igh witha normal incandescent bul) use rough service ‘bulbs to avoid breakage. The hot flament of an Accidental broken Bub can igs fie or Fig. 1. BNW ackra pont arrows} ou Keep sparks, lied matches, and ary open flame away for the top ofthe barter. Hyaro- ‘gon gas emined bythe batery is hon anna Ble. Any nearby source of anion may cause the To raise car safely 1. Patk the car on a fat, vel surtace, reo 2, Place the jack in positon. See Fig. 2. Make sure the jack + Nove kay fool or parts in he engine compart {is res ing on flat, solid ground. Use a board or other sup- ‘ment or on tp ofthe Batty. They may fl into ‘part to provide a fim surtace forthe jack, necessary Confined spaces and be afc rerove, be como cag In bells oF other rolang paris ‘when the engine s started, ov cause elecical Shorts ard damage fo he electrical system ‘Tho fu system i dosgnad to retain pressure ‘evan when te rien iff When working wih {tha fuel systom,fosen the fue Pes stow oa Jow the rescual pressure to sipate gradually. Take precautions to avald spaying fuck. Lifting the Car For those repairs that require raising the car, the proper ack ing points should be used io raise the car safely ad avord dam: age, There are four jacking points from wich the car can be safely raised, The jack supplied withthe car by BMW can only bo usod atthe four side points—just behind the front wheel ot justin front of the rear wheel. See Fig. 1. ” WARNING — a ] + When raising the car using a oor jack ra y= ‘raul lt, caretuly position the jack pad to pre | | vent damaging the car body. A sutabe iner (wood, rubber. et, shouldbe plsced between the ack and the caro prevent ody damage Fig. 2. EN stnoa ack correct postoned Under rent Bena + Walch te jack closely Make sure it stays stable ‘and doos rot shftor it As the cars 960, the |__carmay rot sighty and ine ack may sit 3, Raise the car slowly while constantly checking the po- ‘ion ofthe jack and the car. 4, Once the cars raised, block the wheel that is opposite and farthest from the jack to prevent the car ftom unex: pected rling. GETTING STARTED010-4 FUNDAMENTALS FOR THE DO-IT-YOURSELF OWNER WARNING — * Do not rayon he transmission or the emergen ‘9y bake lo kage the car trom rating. Thoy are nota subsitute for positvey Blocking the oppe ‘te whe. + Never work under acar thats support only by 4 jack Use jack stands that aro propery ce ‘janet to supeert the car: See Tools. To work safely under car 4. Disconnect the battery negative (-) cable so that no fone else can start the car. Let others know what you wil bo doing 2. Raise the car slowly as described above, 8. Use atleast two jack stands to support the car. A jack is a temporary liting device and should not be used alone te suppor the car while you are under it, Use jack stands designed for the purpose of supporting a car. For mere information on jack stands, see Tools below. WaARNiNG — o net use weed, concrete blocks, or rcks 10 syp- porta car Wlood may spit. Blocks or bck, whe Song. ate net designed for thal Kr of load, and ‘may break ar colgpse. 4. Place the jack stands om a fim, solid surface. Itneces- ‘sary, use a lat board or similar Solid object to provide a firm footing. 5. Lower the car slowly unt its weight is fully supported by the jack stands. Watch to make sure that the jack ‘sands do not ip or lean as the car settles on thom, 6. Observe al jacking precautions again when raising the ‘ar to remove the jack stands. ADVICE FOR THE BEGINNER The tias inthe paragraphs that folow are general advice to holp any do-t-yourself BMW owner perform repairs and main- tenance tasks more easily and more professionally. Planning Ahead ‘Most ofthe repairs and maintenance tasks described inthis ‘manual can be successfully completed by anyone with basic tools and abites. Some cannot. To prevent geting in too deep, ‘know what the whe job requires betore staring. Read the pro- ‘cedure thoroughly, rom beginning to end, n order to know just ‘what to expect and what pats wil have tobe replaced, ADVICE FOR THE BEGINNER Cleanliness Keeping things organized, neat, and clean is essential to do- ‘gia good aby Whi orig under the herxt, redo con, wil protect he finish from scratches and other damage. Make ‘sure the car is relatively clean so that crt under the cover does ot sratch the nish. Ay repair jb willbe lass woublesome if the parts are clean. For cleaning old parts, many solvents and pars cleaners are available commercial. For cleaning pats prior to assembly, commercially available ‘aerosol cans of carburetot cleaner or brake cleaner are handy touse, and the cleaner wil evaporate completely. WARNING — Vietualy all solvents used for cleaning parts ave ‘ny flammable, especialy im aerosol form. Use wit exome care. Do net smoke. Do not use tase roduets near any source of spans or fame. Let any solvent or clearing product cry completely. Low: pressure, dy compressed air is helpful if avaiable. Also, use (nly int tree rags for cleaning and eying. WARNING — Avot geting tool or clothing near the betty. Bat tery elect is 3 corosive ace. Be caret wih brake fui, as itcan damage the car paint. Final seep ruber parts such as hoses ana als ee 107 21 or gasoline, as they wil cause the material fo ‘sofen and fa premature Non-reusable Fasteners Mary fasteners used on the cars covered by this manval ‘must be replaced with new ones once they are removed. These Include but are not ited to: bolts, nuts (seltlocking,nyiock, .), cotter pins, studs, brake ftings, rollins, clips, and wash es. Genuine BMW parts should be the only replacement pats Used for this purpose, Some bots are designed to stretch during assembly and are permanent altered, rendering them unusable again. Always place fasteners where insiucted to do so. See an authorized [BMW dealer for appicatins and ordering information. Tightening Fasteners \When tightening thebolts ornuts tha attach a component itis ‘always good practice to tighten the bots gradually and evenly to avoid misalignment or over stressing any one portion of the ‘component For components sealed wih gaskets, this method etps to ensure thatthe gasket wil seal properly and completely.FUNDAMENTALS FOR THE DO-IT-YOURSELF OWNER 010-5 Where there are several fasteners, tighten them in a so uence alienating between opposie sides ofthe component Fig. 3 shows such a sequence for tightening six bolts ataching atypical component. Repeat the sequence unt llthe bolts are ‘evenly tightened to the proper specication, For some repairs a specific tightening sequence is neces- ‘sary, ora particular order of assembiyis required. Such spacial conditions are noted inthe text, and the necessary sequence is doscrbed or ilustated. Where no spectc torque is listed, Ta ble a can be used as a general guide fr tightening fasteners. Fig. 2, Genera sequence or ates tohiering ute asters WARNING — ‘Table a 1s 2 gonoralroforance only The vats ist ein the fabie are not mended obo used as as ‘tue for torques spociealy called out the foxt throughout ts manual. Nore— + Metric bal classes of grades are marked on the bolt head. + 9 not confuse wrench size with lt lamer size Fr a listng ofthe conten wrenches used on var- (008 bot diameters, see Basie Tool Requirements General Bolt Tightening Torques in Nm (max. permissible) Bolt Class (according to DIN 267) diameter 55 | 58 68 88 | 109 Ms 2s) as) 45) 6 | 6 Ua as) 6 75) 10 | 1 twee fof oe fe cd Bo we [we mo) ww NS mia em) 98 | to | 100 mie a4 | 328) 180 | 200 | 200 8 a0 | 17a | 210 | eo | 80 Gaskets and Seals ‘The smoothest metal mating surfaces stil have impertec- tions that can allow leakage. To prevent leakage at critical joints, gaskets of sof, for-fiting material are used to fil inthe Impertectons, ‘Tobe most efectve, gaskets are designed to crush and be come thinner asthe mating parts are bolted together. Once a ‘gasket has been used, is no longer capable of making as (00d a seal as when new, and is much more likely to leak. For this reason, gaskets should not be reused. Aways plan to use ‘new gaskets for any reassembly. Some gaskets—such as headgaskets—are directional. Make sure that these are in- stated correatly. This same logic applies to any part use for sealing, inclucing rubber O-rings and copper sealing washers, \nplaces where a shat must pass through a housing exible lip seals are used to keep the lubricating ollor grease trom leak ing out past the rotating shaft. Seais should never be roused ‘nce they have been remaved. When removing a seal, becare: {ulnotto scraich or otherwise damage the meta surfaces. Even ‘minor damage to sualing suriaces can cause seal damage and leakage. ‘The key 0 sealinstaiation sto get the Sealin straight without damaging it. Use an object that isthe same ameter as the ‘seal housing to gory and evenly crive it into place. ita proper size seal dver isnot available, a socket ofthe right size wil do. \Whon instalinga seal, coat the entire seal with oll help itgo in more easily. Seals are directional. Make sure tha iti in- stalled withthe lp facing the correct way. Normally the ip faces the inside. Note the instalation direction ofthe old seal before removing it Elect AA great many electrical problems can be understood and solved with only a itte fundamental knowledge of how elect caloiruits function. al Testing Electic curent oly flows in a complete circuit. To operate every electrical device in the car requires a complete circutin- luding a voltage source and a path to around. The postive (+) side ofthe battery i the original votage source. and ground is ‘any return path to the negative (-) side ofthe battery, whether through the wiring hamess or the car body. Except fr portions ‘ofthe charging systom, al electrical curent inthe oar is direct ‘current (2C) and flows from positive (+) to nagative (-) ‘Switches are used to turn components on or of by complet Ing or interrupting he cul. A switch s “open when the circuit |sinterupted, and “closed” when the crcutis completed. Fig. 4 shows a complete cicutt schematcally. See 600 Electrical ‘System—General for electrical troubleshooting ADVICE FOR THE BEGINNER