Honda Bmw 5 Service Manual

							
01 0-1 
010 General 
General ........................... .01 0.2 
How to Use  this  Manual ............ .01 0.2 
Warnings.  cautions and notes ........... .0l 0.3 
Getting Started .................... .0i 0.5 
Safety ............................. .O1 0.5 
Lifting the  car ........................ .O1 0.5 
Raising car ......................... .O1 0.5 
Working under car .................... .O1 0.6 
Advice  for the  Beginner ............ .O1 0.7 
Planning ahead ...................... .O1 0.7 
Workshop practices ................... .O1 0.7 
Non-reusable fasteners ................ .O1 0.7 
Tightening fasteners .................. .O1 0.8 
Gaskets and seals .................... .O1 0.9 
Electrical testing .................... .O1 0.10 
Wire  repairs ........................ .O1 0.10 
Buying  Parts ..................... .01 0.11 
Genuine BMW parts ................. .O1 0.11 
Non-returnable parts ................. .O1 0.11 
Information you need to  know .......... .0l 0.12 
Service ........................... 01 0-1 3 
TOOIS ............................. 010-13 
Basic  tool requirements ............... 01 0-1 4 
Jack  stands ......................... 01 0-1  6 
Oil  change equipment ................. 01 0-1 6 
Torque wrench ...................... 01 0-17 
Digital multimeter .................... 010-17 
BMW  special tools ................... 01 0-1 8 
Emergencies ...................... 01 0-1 8 
Changing  a tire ...................... 01 0-1  8 
Jump  starting ....................... 01 0-1  9 
Indicator and  warning lights ............ 01 0-1  9 
Towing ............................ 010-20 
Spare  parts kit ...................... 010-21   
						

							
01 0-2 
General 
This  section  is intended  to help  the do-it-yourselfer  get start- 
ed.  Tips  on workshop  practices, basic  tools, and a quick refer- 
ence guide  to emergencies can be  found here. 
WARNING- 
Do not use this manual unless you  are  familiar with basic 
automotive  repair procedures and safe workshop 
practices. 
0 This manual illustrates the worl
						

							
General 
0 GENERAL, MAINTENANCE covers general vehicle infor- 
mation 
(010 General)  as well  as the recommended  mainte- 
nance schedules  and service procedures to  perform BMW 
scheduled maintenance 
work (020 Maintenance). 
The next seven sections 
(1 through 7) are repair  based and 
organized  by three digit repair  groups. Most major  sections 
begin with  a GENERAL repair  group, 
e.g. 100 Engine-Gen- 
eral. These 00 (double zero)  groups contain descriptive the- 
ory  of operation and system troubleshooting  information. The 
remainder  of the  repair groups within  a section contain the 
service and repair information. The last  two sections contain 
detailed electrical wiring schematics and  OBD 
II scan tool and 
diagnostic  information. 
Warnings,  cautions and notes 
Throughout this manual  are many  passages  with the head- 
ings  WARNING,  CAUTION, or NOTE.  These very important 
headings have different meanings. 
WARNING- 
The  text under  this heading  warns of unsafe  practices  that 
are  very 
likely to cause  injury, either by direct  threat  to the  per- 
son(~)  performing  the work 
orby increasedrisl( of accident  or 
mechanical  failure while 
drivinq. 
CAUTION- 
A CAUTION calls attention  to importantprecautions  to be ob- 
senfed during  the repair  work that will help prevent acciden- 
tally  damaging the  car or its parts. 
NOTE- 
A NOTE  contains  helpful information,  tips that will help  in do- 
ing  a betterjob  and completing  it more  easily. 
Please  read every WARNING, CAUTION,  AND NOTE  in 
001 
General  Warnings  and Cautions  and as they appear  in re- 
pair procedures. They are very  important. Read them before 
you  begin  any maintenance  or repair job.   
						

							
. 
General 
WARNING- 
Never run the engine  in tile work area unless  it is well-ven- 
tilated. The exhaust should  be vented  to the  outside.  Car- 
bon  monoxide  (CO) in exhaust kills. 
Remove all neckties, 
scarfs, loose clothing,  or jewelry 
when working near a running engine  or power  tools. 
Tuck  in shirts.  Tie long hair and secure  it under a  cap. 
Severe injury  can result from these things being 
caugiit 
in rotating parts. 
Remove rings, watches, and bracelets. Aside  from the 
dangers  of moving  parts, metallic jewelry  conducts 
electricity  and may  cause shorts, sparks, burns,  or 
damage to  the electricalsystem  when accidentally con- 
tacting  the battery  or other electrical terminals. 
Disconnect  the battery negative 
(-) cable  whenever 
working on  or near the fuel system  or anything that is 
electrically powered. Accidental electrical contact  may 
damage  the electrical system  or cause a fire. 
Fuelis highly flammable. When working around fuel,  do 
not 
smoke or  work near heaters  or other fire hazards. 
Keep  an approved fire extinguisher  handy. 
The  fuel system is designed to retain pressure  even 
when  the ignition is  off When  worlcing  with the 
fuelsys- 
tem, loosen  the fuel lines slowly to allow the  residual 
pressure  to dissipate gradually.  Take precautions  to 
avoid spraying fuel. 
. Illuminate  the worlc  area adequately and safely  Use a 
portable safety light  for  worlcing inside or under  the car. 
A fluorescent type 
light is best because it gives  off less 
heat.  If using a light with a normal incandescent bulb, 
use  rough  service  bulbs to avoid 
breakage. The hot fil- 
ament of an accidentally broken bulb can ignite spilled 
fuel or  oil. 
Keep sparks, lighted matches,  and any open flame 
away  from the top  of the  battery.  Hydrogen gas 
emitted 
by the battery is highly flammable.  Any nearby source 
of ignition  may cause the battery to explode. 
Never lay 
tools or parts  in the engine compartment  or 
on top  of the battery. They  may 
fallinto confinedspaces 
and  be difficult to retrieve, become caught  in belts  or 
other rotating  parts when the engine is started,  or 
cause  electrical  shorts and damage to the electrical 
system.   
						

							
General 
Much of the necessary maintenance  and minor repairthat  an 
automobile will need  can be done  with ordinary  tools. Below 
youll  find important information on  how to work  safely, a dis- 
cussion  of what  tools will be needed and  how to use them. 
Safety 
Although an automobile presents  many hazards, common 
sense and good equipment can help ensure  safety. Many ac- 
cidents  happen  because  of carelessness.  Pay attention and 
stick to the  safety rules in  this manual. 
Lifting the car 
4 The  proper jacking points  should be used  to raise the  car 
safely  and avoid damage.  The 
jack supplied with the car can 
only  be used  at the  four  side points (arrows)  just behind  the 
front  wheels or  just in front  of the  rear wheels. 
WARNING- 
. Never  work under a lifted car  unless it is  solidly  supported 
on 
jack stands  that are intended  for that purpose. 
When  raising  the car using  a floorjack  or hydraulic  lift, 
carefully  position the jack  pad to prevent damaging  the 
car  body. 
* Watch  the jack  closely.  Male sure it stays  stable  and 
does  not shift  or tilt. 
As the  car is raised,  it may  roll 
sliahtlv  and the 
jack mav  shift. 
Raising car 
- Park  car on flat,  level  surface. 
- If changing a tire, loosen  lug bolts before raising  car. See 
Changing 
a tire. 
Place  jack into position. 
Malte sure  jack is resting  on flat,  sol- 
id  surface.  Use a board  or other support to provide a firm sur- 
face  for jack,  it necessary. 
- Raise car  slowly while  constantly checking position of  jack 
and  car. 
- Once car is raised, bloclc wheel  that is opposite  and farthest 
from  jack to prevent  car from  unexpectedly rolling.   
						

							
(General 
WARNING- 
Do not  rely  on the  transmission  or  the parking brake to 
keep the car from  rolling. They are not 
a substitute forpos- 
itively  bloclcing  the opposite wheel. 
Never 
work undera  car that is  supported  only by a jaclc. 
Use  jack  stands  designed to  support the car. See 
Tools. 
Working under car 
- Disconnect negative (-) cable from  battery so that  car cannot 
be  started.  Let others  know what you will be doing. 
CAUTION--  Prior  to disconnecting  the battery, read the battery discon- 
nection cautions given  in 
001 General Cautions and 
Warnings. 
- Raise  car slowly  as described  above. 
- Use  at least  two jack  stands  to support car.  Use jack  stands 
designed  for the  purpose  of supporting  a car. See  Tools. 
WARNING- 
* A jaclc is  a temporary lifting device  and should not be  used 
alone  to support  the car while you are under it. 
Do not  use wood, concrete 
blocks, or bricks to support 
a 
ca,: Wood  may split  Blocks  and bricks,  while strong, 
are  not designed  for that kind  of load, and  may break  or 
- Place jaclc stands  on firm,  solid  surface. If necessary, use  a 
flat  board  or similar  solid object  to provide  a firm footing. 
- Lower  car slowly  until  its  weight is fully  supported  by jack 
stands.  Watch to 
make sure that the jack  stands  do not  tip or 
lean  as the  car settles  on them. 
- Observe  all jacking  precautions  again when  raising car to re- 
move  jack stands.   
						

							
General 
ADVICE FOR THE BEGINNER 
The tips that follow are general advice to  help the do-it-your- 
self  BMW  owner 
periorm repairs  and maintenance taslts 
more easily and more professionally. 
Planning ahead 
Know  what the whole job requires before  starting. Read the 
procedure thoroughly, from beginning  to end, in 
orderto know 
just  what  to expect and what parts will have  to be  replaced. 
Workshop  practices 
Keeping things organized, neat,  and clean  is essential  to do- 
ing  a good  job. When working under the hood,  iender covers 
will  protectthe  finish from scratches  and otherdamage. Make 
sure the car finish is clean  so that  dirt under the cover  does 
not scratch the iinish. 
Any repair  job will be less troublesome if the parts are clean 
For cleaning old parts, there  are many solvents and  parts 
cleaners commercially  available. 
For cleaning parts prior to  assembly, commercially  available 
aerosol cans  of parts cleaner  or brake cleaner  are handy to 
use, and  the cleaner will evaporate  completely. 
WARNING- 
Most solvents  used for cleaning parts are  highly  flammable 
as  well  as toxic,  especially  in aerosol  form. Use with extreme 
care.  Do not  smoke.  Do not use these  products indoors  or 
near  any source  of heat,  sparks  or flame. 
Non  reusable fasteners 
Many fasteners used on the  cars covered  by this  manual 
must be replaced with new  ones once they are  removed. 
These include  but are  not limited  to: bolts, nuts  (self-locking, 
nylock,  etc.), roll pins, clips  and washers. Genuine BMW 
parts should be the only replacement parts  used for this pur- 
pose. 
Some bolts  are designed to stretch during assembly  and are 
permanently altered, rendering  them unreliable once  re- 
moved.  These are known  as torque-to-yield  fasteners. Al- 
ways replace fasteners where instructed  to do  so. Failure  to 
replace these fasteners could  cause personal injury 
orvehi- 
cle damage.  See an authorized  BMW dealer  for applications 
and ordering information.   
						

							
General Tightening fasteners 
When tightening the bolts ornuts on acomponent,  it is always 
good practice to tighten the bolts gradually  and evenly to 
avoid misalignment  or over-stressing  any one portion of the 
component.  For components sealed with  gaskets, this meth- 
od helps to ensure that the 
gasket will seal properly. 
WARNING 
- 
Table a: General  bolt tightening torques in Nm (max. 
permissible)  is 
a general reference only The values  listedin 
the  table  are not intended  to be usedas  a substitute  for tor- 
ques specifically  called out in the  text  or in manufacturers  in- 
formation. 
4 Where  there are several  fasteners, tighten them  in a se- 
NOTE- 
* Metric  bolt classes  or grades  are rnarlced on the  bolt  head. 
* Do not  confuse  wrench size with bolt diameter.  Fora listing 
of  the  common  wrenches  used on various  bolt 
diameters, 
see Basic  tool requirements. 
2 BOO~FNG 
quence alternating between opposite sides  of the compo- 
nent. Repeat the sequence until all the bolts are  evenly 
tightened to the proper specification. 
For  some repairs  a specific tightening  sequence is 
neces- 
sary, or particular order  of assembly is  required. Such  special 
conditions are noted in the text, and the necessary  sequence 
is described  or illustrated. Where no specific torque is listed, 
Table 
a: General  bolt tightening torques  in Nm (max. per- 
missible)  can be used  as a general guide for tightening fas- 
teners.   
						

							
General 
Table a. General bolt tightening  torques in Nm 
(max.  permissible) 
Bolt Class (according  to DIN 
267) 
Gaskets  and seals 
Gasket  aredesigned  to crush and become thinner as the mat- 
ing  parts  are bolted  together. Once  agasket has been  used,  it 
is  no  longer  capable 
;f malting  as good a seal as when new, 
and  is much  more likely  to leak. 
Forthis reason, gaskets 
should  not be reused. 
Some  gaskets and seals  are 
d~rectional. Make sure thatthese 
are 
~nstalled correctly.  In places where  a shaft must pass 
through  a housing, 
flex~ble lip seals are  used to keep the lubri- 
cating 
011 or grease  from leaking out past  the rotatlng shaft. 
Seals should never  be reused once they have  been removed. 
When 
rernovlng a  seal,  be careful not to damage  the metal 
surfaces. 
The  ltey to  seal installation is to get  the seal  in straight without 
damaging  it. Use a seal  driver that is  the same diameter as 
the  seal  housing  to gently  and evenly install into place. 
If a 
proper size seal driver  is not available,  a socket  of the  right 
size will  do. 
Some  seals are directional and special installation instruc- 
tions apply.  Make sure a seal is installed with  the lip facing  the 
correct  way. Note the installation direction  of the old seal  be- 
fore  removing it.   
						

							
01 0-1 0 
General 
Electrical testing 
Many electrical problems  can be understood and solved with 
only a little fundamental  knowledge  of how  electrical  circuits 
function. 
Electrical current 
only flows in  a complete circuit.  To operate. 
every electrical  device in the car  requires a complete circuit 
including  a voltage  source and a path to ground.  The positive 
(+) side of the  battery is  the original voltage source, and 
ground  is any return path to  the negative 
(-) side  of  the  bat- 
tery, whether through  the wiring harness or  the car body. Ex- 
cept  for portions  of the  charging system, all electrical current 
in  the car  is direct current  (DC) and flows  from positive 
(+) to 
negative 
(-). 
4 Switches  are used to turn  components  on or off  by complet- 
ing  or interrupting  the circuit. 
A switch is open when  the cir- 
cuit is interrupted, and closed when  the circuit is completed. 
See 
600 Electrical  System-General  for electrical trouble- 
(LW, 1 shooting 
Wire repairs 
Light bulb 
(consumer)  - Repairs  to a wiring harness require special  care to make  the 
repair permanent.  The wire ends must  be clean. 
if frayed or 
Car body otherwise damaged,  cut off the  end and  remove enough insu- (ground) i Battery lation to complete  the repair. if  the wire is  too short, splice  in a BOZLiEL new  piece  of wire  of the same size  and make two connec- 
tions. 
Use  connectors  that are designed for  the purpose. Crimped 
on  orsoldered-on  connectors are best.  Crimp  connectors  and 
special crimping pliers are  widely available.  If soldering,  use 
needle  nose pliers  to hold the  wire near  the solder joint and 
create a heat dam.  This keeps  the heat and  the solder from 
traveling  up the wire. Always  use a solder made specifically 
for  electrical 
work (rosin core). 
NOJE- 
Twisting wires together to  make a repair  is not  recommend- 
ed.  Corrosion  and vibration  will eventually  spoil the connec- 
tion  and  may  lead  to irreparable damage to sensitive 
electronic components. 
Insulate  the finished connection. Electronics stores can sup- 
ply  heat-shrinkable insulating  tubing that can be placed  on to 
the  wire  before  connecting, slid over  the finished joint, and 
shrunic to a tight fit with a heat gun  or hair dryer.  The next best 
alternative  is electrical  tape. Make sure  the wire is clean  and 
free  of 
solder flux or  other contamination. Wrap  the joint tight- 
ly  to  seal  out moisture.  See 
600 Electrical System-General 
for more  information.