Motor Engine Moteur Motore Motor Motor Motor11 Engine Specifications 1400005 Diagnosis with BMW program /digital tester... Page 11-03, 0/1 039 Checking compression ofall cylinders .......-.. 00/23, 050 Removing and installing engine ......0.s0.000 00/23, 1111160 Renew distributor shattbearings |... Wt 1112000 Removing and installing cylinder head cover . 3H 100 Removing, ling cylinderhead wn 101 ing cylinder head gasket ........ 1217 1217 240 Renewing radial seal intiming case cover 561 Renewing one valveguide - 1218 607 Machining valve seats andvaives . 12/9 719 Grinding eyinder ead mating surface f 12/9 729 Cylinder head water 129 1113000 Removing and inst 13/1 1114175 Removing and installing front end cover 14 180 Renewing radial sealsin end cover .. woes 14/3 611 Renewing radial s alin end cover (clutch ond) a 14/3 1821000 Removing andinstaling crankshaft... an ‘501 Renewing crankst sare 22 srt nkshaft ecco 213 1122000 Removingand installing flywheel .......... 22st 051 Renewing torque converter drivepiate ...... 221 541 Renewing startergearring ...... Bee 1124521 Renewing all connecting rods ...... 24/1 "128000 Ranoving aod inataling allio 25/1 651 Renewing rings of one piston 25/3 1131000 Removing andinstalling eamshati ait 100 Tightening toothed belt ait 140 Removing and installing toothedbelt -....... 312 1133020 ing rocker armshatts - 39/1 031 rockerarms : 39/2 1134004 clearan 3a/t 509 Checking all valves forleaks - aut 550 Removing andinstalling valves... 341 1135020 Removing and installing intermediate distributor shaft 35/1 1141000 Removing and installing ll pump ...... aut 140 Removing andinstalling safety valve ai 1151000 : > ost 502 sembling and assembling water pump : sie 1153000 Removing and installing coolantthermostat sasiavanae 2 83/1 081 Renewing temperature transmitter ..... aveisrave 53/1 1161000 Removing and installing/sealing intake line and carburetor ole 50 Removing andinstalling intl ss 2 6us 051 COMGCIOF ses scseeeeevese es 1174051 Renewing thermovalve .......+ eae an 27 11-0/1woIsie, uersny uo (dug OZ1) MAz uapems 104 uo}si 00st 000% oro Bua we (vot ‘'61) o6t (orett ‘e'98) ook (Gq wey) wn anbsoy KEW 0008 0009 UWL peads oulBue snonunuoa xeW. ___onve oro UWL pede ourBue powywied Kew si + 0099 051 = 0099 ww eeds inoina s04s0n05 088 0008 uw peeds eujbu (ers) sor Ween) 06 (cua) Indino eans9y0 “Xow Liss z (eetwt) stez (Le6et) Lezz 960 - (core) 92 - (a) ww (sve) 08 (up) wus Cvieze @ vovoze (a feze (e g/oze (e ‘suoeoyi9eds a10/8 a708s (erezdeek @ @ wopoms 10} UoIsi0n (. mojoq 100d ‘einssaid Uolsso1dW0D paods oubue ve GuS19M $8018 ojqissiu9 ‘96e66n} “ou! ‘pepeo} Attn} (1yBjem vopejun 10) lun) ues ‘DEO 40} Apeos ‘one 1yBlom/z0mog ~(panuiyuoa) exoua6 - aui6u3 ~~ 004 aroze pow euj6uz suopeoyioads 1-0/4(900°0 °** poo'o) S10 "** O10 $0.0 (0000 * p000°0) zoo too ee (zooo'a + 6681'e) so0'0 + sis'09 (zooo'a + 0091's) so0'o + ssz'08 (Zooo'a + erste) s00'0 + s60'08 (2o00'0 + zost'e) s00'0 ¥ si0‘08 6c/0-1b uapoms 10} uorsi0,, ) wus sapunjAa pue uorsid Ye oouemoyte seam “Bap ‘ssouyBnos a2eung ‘97181070 o10q94 puz ~ 2108 azjsiano a1oga: 3s} — 9108 27181010 03 ‘ozs prepueys — Ipowuawu - 2108 ez zz ete Zoe zee Lee ave le roa sie Gv eee (@ ] v g/oze (@ ja sy0ze (© _ Se eujbu3 suoneoyioads 11-05(4,96-) 9,01~ "de 0} Suu 08 enfen 11ND “4. 28h *** BzP) 9. 08% "" O2z oF peeoy peey sepUIKD LIA Rey Japulyéd ul 9109 971619K0 10} voIsuoWNIP I ‘wapamg 10) Uolsi0A (e000 =" yoo) sr0 "oro www buy — _| enren 40} (ay ULUS a (uy wu asneuxg {1000 + £889) geo'g + 02 ‘ot00%0 + S700 + (up wus rout - 1808 OAIeA 10} 0108, (eer wee) ose oe wo. paieoy oq isn ‘peau sopuno yorum (00°0 "* 9000°0) #600 "** S10" - opin6 0 - (oezs-o/seisro/zsis‘o) eet/z'e1/e ° ouso. 9 (ooo + 8 oo + ‘210q 9pin6 aAlen (oco0'0 “** s000'0) 220'0 = 8100 ‘aouesea(9 pajjeisur yeys 18990u ° ° op (2100°0 + 9890) exo + S4# _ sroqueys 199204 peay sapuik*zbib (vi eee wy e7oze " 1e2e size repo eurbug suoneoyjoads 11-016peoy s9pul[ho us e109 97161940404 uo} 12WID 4 HULYS SION (, “npr yes anien, ‘2/8ue uopoesi09 Wg 7 ‘bop st*~*~*=« BU YDS OJ Sooo = ere so0-0 ee ‘aes =esus 1S ssw | voo0'a — *499'H) 699-9 - SEP | )) ws Wut (isozisien9 Goon — 820 goog S04E yw renew : Sooo ="99" Sooo Se [ eration _ sn on - 6 eA" 2b Ove sroce l rep0w eulbuz suoneoyioads, 1-077 27Uapems so} uoIsion(, - (7000°0 + 2) 0400 + a ogo f Hesse gi + s9 wn © geez) 2 “yooo: 0+ Mae ® o100 + 99 (uy) wun par eseaqueso sr -epp o10g bueoa : - neuer a si weusaeID = LZLF (2610°0 ¥ 60LS'0) 0 + Sm (wy) ww (peoy sopumAo) uy uonsford apin8 aatea (ezs'0/2siso/zsis0) eeL/eeN/et - aw 2181010 © sero). 2 ‘0000 + S42 croa + 4 (up) wus (E1000 + @) perp) E800 + ove GHG S anisw $608 | oc feo ennsr cr) (wieze vo/0ze 1eze s/07e repel oujBu suoneoyoads wou 1-078{8000°0 ~ 9970) 020° ~ yz LUapems 10} UojsieA (. (BIER sear $250 1s ony (20209 - yagoa) 9200 = ogz | oe ieouns ($000 seve) S209 ~ owes [ on GSeEg seen Boorse | ow puntos pz - 09 < ves) 209 res [cw ona ——_(8800° ese 209 x65 pas GSS eweo SEO oo on © £880 —ze067) 2299 — 99 jew ~ soBeis puuboy weysqueID "= 1ZLL Vee v o/0%e ize Sr0ze ‘pon euj6ug, suoneayjzeds 11-019{8000'0 9990°4) 9209 + oprez uapems 101 YoIsion (, (up) wi 02}81900 puz, 1.200'0 - 000°) esoro + OF 8000'0 — zag) 0200 + gar \{z00-0 - +228) eso-o + 92'S? 000'0 — zoo + (200-0 - 785 esor0 + 908% (u) wu azysieno ist (a) ww puepuers wpm Suueeg ‘apin6 yeysyuers — sabers pub, suoneojoads, - an 21000 seo 0800 a _ - (ezoo0~**zt0') oz00"*" 000 par reypes ‘Keys Buueog £0009 sepa) 2200 aaag = 201-0 Gipeg ome _ ‘wok oe, 0009 = pao, 9200= ee a (uy —__pavansono pue a _ 000° — 2°00) guor9 - 808% (uy wos ‘ang $0009 eens @00=egg (0000'0 ~ geared O20 9 — 929% (wy wa pas 92181900 1S) (pant 19) sBulze9q YM WeYsHUEID ©” LZLL Gvieze v 9/08E eee see report aul6ug 11-0/10(ee00'0 * seeoe) v0 F 8 a ae uspoms 10} st 7 ‘ss0uy6no4 e2euns. _ - i no Bulzeoq ojaresiuod xeW L (Ge00'0 — va6s'2) 1'0 > 98 ~ ey wus ueio, (6s00'0) _ (jeusno| Bueoq ysowa;no idne yeysyues> yim) Teusno! Bu 2 (900"0 ~ 1£00°0) e910 "0800 | wy was sz 0100'0~ 92524) $200 pay ooo _oese'b) 600°0 or (24080 oro) $209 srpp )) wu 9z18s9pun IS 01.00'0 — 74-4) S200 — 05008 = zi2e'0) $29°0 ~ gorse yuu prepuers sojowresp teusnol Suyie0g pue 61q~ soBeie punGoy (Ponunuos) s6une%q yumm weusMUesD ~~ Z4L Cvieze vov0ze tee sv0ze = euj6ug suonesyjoads 1-01 27(Ge00'0 + 910'0) ro+¥0 (e (seo0'0) 1 (@000"0) zoo ( sie uapomg 10} uoIss9n (, 908) 1981U09 uluuoeU EN ip (ul z9'e) wu 26 “ep (ut pore) wus 08 xeW, qui} 281s EW ~wo8eouereau euAp en — reowahig "zu pn Shes see Cvieaet@ ¥ 9707s (@ . vege (e sroze (© ‘pew eu6uz suopeoyjoads 110/1220000 + jygy) $000 Gono 988) e542 (esb6'0 *- “zzv6'0) oor-vz spams 10} uoisi9, (, ep nu ip “Wxe ~ Bulysng Buyeog pus yews 0 0 oan + 80) gh iam, ep ou be ¢ ade ~ a | tag a pee nete-eiog par supuveg (yoo = sits) 10 + OeF (uy we pus 0 pus 619 40 49% pou Bunsauu09, ‘s6ujleaq pue pos Bugseuuog = (zro0e0 | __= - '92'6) ww sez dde we (e000) 20 Oo = (e000) z0 ei _ a (se's) an — Crewe ] 1eze l repen au6ug suoneoyioads 11-0/13 anuapams 10} uolsi9A (. 08.0 0p _| en sim (s100'0) p00 = 'g) wu ost ie ‘says Buze9q ut pos 6unosuu0s .d wou) uoneinep “xER (9200°0"** 9000°0) 2900" F200 www ripe: ‘Aejd Buueag, ‘wu az/si0n0 z 9601S ww ez/sien0 | ees wu sa yous Suneog Beis puLBeL reaped ‘Aeid Suess wus 9zsi900 2 abe1S wus azisian0 1 ag wu puepues = 099 “Mi ~ ssouraIMN 24s BuLeEg - ‘sebe}s puyboy (banuquos) sBuyea um pos BuaDeuUon ~~" HZ LL (up wu vy 9/0ze 9/08 suoneayioads repow eu16u3 11-014218 siajoweip uosid nooup $9) ano woned uorsid pue uojsseiduos jou pue — (e000 + se1000) 160 = S800 (e000'0 = 658910) 600°0 = er'08 ez08 ypu} mouse Ue pue “(wW) 66 se0pi'e) 600% + e662 Sen000'F beer ee 60% at: ane - - 40 payound) dnes6 iu6i9 A — (uorsig “* “szub (u00) 2 = OO (wreze ] v g/0ze Eze 9/0ce eu6ug suoneoyioeds 11-0115 an{ezo0'0 ** 9100°0) 20" (wzo0r0 *** 2h00"0) 290% ono ono (20 +) dnou (eam sas 1010 - 00% (e00'a * oz00"0) za'0 “0s (geoo'0* re00"9) 260°0"** 09070 (ooo woo) so" eo Go aoos0 FO - 0000 2200 ~ gg, (80000 ses0-0) 2209 “os - ~sBup uotsid "Seb - eo zo wy aw eso 2109 uid voIsid ° o ‘srooo + *98°°) poor0 + 2 (up) ws 9109 uid vorsiag eo) or (0) 5 (ouBue ue jo suoysid ajojdwoa aun ui ~_(panunuos) uoisid *** SLb vovoze . s/0Ze cee eulBu: suopeoyjoeds ma 11-0716(Hed peyojeut & o1e uoysid pue uid uorsid) soyya60} uid uoysid pue uojsid move! sKEMIy (¢ wened Mung leroads— pepueys Nia 01 10N (; Wepems 20} UOISIOA Ce 000 suoisid sy “400° 90070 (oz000'0** yooo0'e) soo" (quoysid ut souev29|9 uid uoIsid (240000 ~ r19se') P20 zz o- (w) wus so.owerp eusoreg — - (uid worsia ***sz ib (v200'0** 21000) ze00 ~~ o€00 (ui) wa suoisid sy (ozov0** g000'0) zs0°0*** ozo (a) wus 0" 68000) o8'0"*"sz0 _ | ta ans (6200°0 ~ 564-9) 2200 pep ‘p000°0 ~ 0100 ~ ) wus (Penujuos) sun uorsig "sz iL v onze 190 9/0ze - pen auibu: ‘suoneoyioads, mes s10/17 an(2000°0 + gzg yt) 600°0 + gyy uapems 10) uo1sie (. $100°0 + veoo G28 | cxee $58 Love G8 eee ee {ero + '98"" pepo soe (or) aus peay spay wep 2109 (2200 ~ gu1g1) $80°9— gray (22000 ~ prec) $809 gop (22009 111.19 809 “os GEE menses (2200°0 ~ ezezt) $90.0 - om (8200°0 ~ sen) Gon sey GEE oor e8 “owe ; : aain9p Bu man veusweg “ten nie "ns = ss au)6ug suoneoyoeds 110/18uapamg 10} UoIsi0A (. ee _ T Wi9a) jo J8quNN ees teze (e00jpua - wo) sequinu uoneaysnu@pl yeusuies uo toyoords yoq pauiood *** Le LL - (ouyse ) waa wpm 8a He (i200'0 = v6se'0) o80'0 ¥ 608s'9 (ort) s6a6-z2 (i000) z0 (6e00'0 "** ¢200'0) 10 *** 6500 {(7000'0 + 91497) 8000 + ogy e100 + 8) Soop + (70009 + exe) $009 | coy 000 + 44-1) 8000 + i a8 t zc $008 tose Gv! eze vy 9/0ze Lee voce suoneoysoads ‘eubug 11-019 27(ozo0' * 9000'0) zs0'0"** 8100 E1000 + ve00- Gio wer Soe uapamg 10} U0Is19A (, ‘aauereoyo Byjuurs 49400u “PIP yeys 109005 ( oF (ooo + 889% iy 4 SA OF og oF ( s20) mn 'B000°0 + 4199901 ut "1p e104 Bulysng 10%90u www _Burysng inouimn e404 19x04 ~pisivnvows a (uw) war chen aspszt Gv ee eee v 9/0ze 9/028 ads uo saquinu worn yous areipawoi uo yey901ds oq payiooL *~ 11-0720(44 @1 1070) wus e°9 :(renea 40 yy ow smaza0 fa @(e600°0) sz"0 (8129904 fone W811 Ka Yes0w0W) omjesodwey ‘WeysieD peewano aj6uls pur sped isi uopems 10) 4apuyko us deyoro aaron, 2x01) uoyssesdusco uo vonenioe ener SONA PELL Gvieze Vv o/oce eee ooze | leon 16 suoneoyjoadg ome 11-0/21 ameeL'0=1sneuxa, eat= rr Omg 104 VOISION <8 Oo 60 | Scere = Sve v 9/0¢e ] 0 8/026 | een eujBu: suoneoyjoads ous 11-0725 277 wavs 08 MOL YS Op MOL VS 0¢ MOL AVS anny - - 05+) 2, 0b + wo — ob avs us 0s M 02 AVS w +) de Ob = 03) ov avs ry 05 02 avs =pei6800 GH oweu-pueg “ay ib wen 98 (unaye jo ainsseig Gviee vy 9/028 Leze 9/07 (euenbsn’swid'dwiy —aBueya Jeu Ham — (suent gn ‘side 1 @Buey> uy now Guyai)1eq ——_(eanssoid a6 somos due} Suuiem waishs woneouq77 yes0ueB woneojsqny euj6ue) Aiddns 1 sropt suoneoyoads 11-0726(ese ‘sez) sv°0 DEMS avs O¢ MS avs 0 MSL avs 9¢/0-LL aBed ose 998 (, ‘Vapamg 10) UOIss9A (, (wondunsues Yo “xe 05 m 02 aVS (ponuyuo) ~ Aiddns 110 * “oF LL ¥ s/oze wsvoze prow auj6ug suoneoyjoads 11-0727 278(1200"0 *** 9000°0) rs0°0 *=* 910°0 19000°0 + ggg) 210°0 + Croo'a + 2°99) erara + + (70009 ~ pogs'0) 110°9~ gy (ooo + zex't)z0 = wy (ears re 8 uopams 104 uoIsi9A (, Suysnoy uj yeyswies ‘ANUS OAUP 10} 108 yowelp yeysuied/yeus ona Ge wos Dor edhy 1895 waned duind 10 dun wo" est Gvreze vsroze = eee sroze POW eui6ug suoneoyisadg 11-0/28emo) Kem-3u0 (ave) se vapams 10} uolsien yz) $99 (92) 89 (ev eieo see ew - (caus | (1000 ~ gegp-g) W007, _Seoaa'0 - $549) gaar9 = 76 _ (w) wus 21000 + gocj-q) £00 + zy ‘reoao + £8840) gg + 6 ) ww ‘usepoeq Ieynsee6 dund Yo aiqissiuiieg su nd Wo 40 Keidpue xew sjeayauee6 dund yo 40 1481} jeoynueed duind jo 40) Butsnoy 0 widog vavze 9/028 (Penunwos)— dun WO" FLL Wepow yroads eubug 11-0129 27wapamg 10} uojsi0n (. = (ss) eb (4) D0 Bingieid = Gs) eb (@.)o.__Swauinssul Sexe, .2801,, = ) 0% (4) 9. Bunqusid = 5 (4) 0, sWownsU) sexe, ,.uedo,, tuied Buiuoums = ~ moiiek Binguora = 7 nia ‘Sivewnnsuy sexe. ones 04 40 10109 = 992 02 3d Bingisid = zbev is 1A ez ~ stuswnnsuy sexo dk, = Ginquaig 10 swownnsu| sexo, | ren es @ ade 5 1 = 08 kup ene 20) S-180H **“DLLL Gogo ¥e0'0) 70 F 80 (u)) ane yooyar soyjodu| pue | ‘Bujsnoy ul Buy 12009 uaamied deo duind voyemn "1S Hb Cv ieee va7oze eee aroce | ae eu/6ua, suoyeoyioeds, 11-0730ara aes WN OW 49014 s0pul wopems 10) uorsian (. yp019 ouBue 48 Aajind Buluosuay yooig sujbue we8y 49109 pus spo1g auj6ue WoL sdeo Buyeoq weW jeayue19 pue yooiq oui6ua “LL LL sonbioy BuyvoryBi Gv exe Leze vavoze s/0ze suoneoijoads eul6ua 110/31 anJ009(4 486) 9.SE Xewl) joo oujBue YUIM(, Uapams 10} UOIEIOA (. 29h09 pus quoH, pue 9 4apul|Ad Uo 1@n00 puen peoy sepuitha 01 48409 194904, uyko uo 49409 @piNg, 9 W peey s9pulifo uo 19.09 Gv ee eee v 9/oze ¥ 9/026 suopeoyjoeds aui6u 11-0/32wal wid WN wat wid WN 8 Wany or sodwep uonesain und ye8a-n sedwep wonesqin "=" eb wat wid uN (ajeysqueso oF rosunnig — yeaumdig *** ebb wat ‘aN e419) WN ues 019 ourbue or dung wat wie wn nid utesP 110 dung =" eri (Penupuos) sonbio} BuworUBiL v9/oze 9/028 repow suojeoyj9eds eulbug 11-0733 an{20u0 fyuo syjoq asn ‘si0q jue .o2 = smd (ya 2 WN 42x01 wo 109 dwseIg ‘sGuyeog wim $10990u "~~ ECL wai wd on 9. W28IP 0 181depy wal wd aN ob Wyeysues L 0 19490148 110g poyioo. weusuies "*"LELL wal wey, uN suoq pus Bia =Buuleoa wim po Bundewuog “== we EL (penunues) sonbio} BuIvOTNBIL (i. wleze vg/0ze MPOuT eae sroze c eul6ug, suopeoyjoeds 11-0738LUapemg 104 UO}s10A (« 6s c9Y war e0"""90 we, sz" 6's WN (ww tx 8 w) vonesuqn) yeysiue> ‘adj Jo 10} Sma, wal dy uN ~ ploo eubus yim = Guowoje hememouny e1qveoeidos) s0H14 10 moyiIng ww st x 02 W ‘Bursnoy, OAIRA 10 eAlen jolia1 ainssaig Sou] pue “aru war wid wn 8.H1 x2010 auybue of din’ ng war wid uN 9. Sujsnoy und yo uoo108 pug a — wa wy uN und Wo" Ww {Penunuos) senbioy Suluan4Bu, T Gwreze vo/oze vepow Leze vy s/oze eulbuz suopeoyioeds 11-0738uapams 10} worsi9n (. Projwew ysney plojiwew ysneyxg "*" ZOLL uN 8 W yoo1a eu6ue yum duind 115m p wip duind s9ye7q ~*~ 4S LE (Panuquos) senbsoy BuueWuBLL Gvieze Leze ¥ 9/0e 3/028 suoneoyjoeds pow eubua 11-0736uapamg 10} UOIs19A (4 wd (ew) WN _2u1Bua uo yex201q uoddn WN __2UiBue uo rey081q woddl (oL w) weeg Bujysng aqqns) ‘s6ugunow ouj6u3 "ye 41 wn Binquoid 4 JW S188 lenuoa uojssjwa ysneyxo (Couuoy)) ennisuesieey --~ pz bb (benuquos) sanbio} Buvany6i, Gvieee Vv 9/026 aa eee 9/086 tenon eulbu; suoneoyjoadg 7 11-0/37 27vapams 10} uorsien (, -2pIn6 onjen pue ways anjer uosmtoq eoueree|o Bujuuns oAjssaoxa °s “usom 10 UaHOsq Jug 61 91R Bujujeig “YyBjom pue ounjexodwo; Gujesedo jeuo, Wo ou6us mou een ~ neu jourimuondunsuoo yo ou ‘we wun (st 0005). 0s £snoge po1oA09 sey oPIYeAO4LOUE po!nswets oguED LoNUNeU uonduinsuos yo Buyyjwue}eq Cvi cee vores Lee 9/026 repent suoneayioeds eubuz 11-0/38‘suoneaisioeds 00s (, vapams 10) uo}si9A (, Ka voitumsueoong = Mu Panos souNEia ‘saoueyewnauto 314 ‘suoRaeUIP Ylod UI pe49K09 9q pINoYS 1 "WIBUBY UI ‘poods wnwxew pouwieyep Aisnoinadd a oun pue 1yBlom ssou6 aquest ‘eunyezedwiar Buy ‘sjuauinsop uo! (qwoneoyjoods prepueys 0} aq ysnus (39 waishs A\ddns Pourew 159} prepuers O£0 OL NIC Aq UoRdunsuod jany BuU|WE}9q Gv rece ] v 9/0ze Leze s/oze. repow suojesyioeds, eujbug 11-0/391100 005 Diagnosis with BMW program tester/BMW digital tester Switch position Itemtested . Connecting programiesier ue +) Battery voltage without po ysumors (15) Voltage atignition coll terminal 15... 4) Ignition coil static cu ) Whe “a va) Voltage dropatconiacibreakersandplugs Rr Capacitor-distributor ...... vovestantoy uo +) Alternator and regulator’... Schl + Dwell angle . wet : Kv Oscillograph display adjustments (basietrace) Cam displacement-distributor assets Contact breaker points ........ Ignition coll polarity Capacitor-distributor Digital tester Ignitiontiming .. Digital tester Centrifugalignition control Digital tester Vacuum ignition control ig ‘Comparative display of cylinde: Balancingcylinder display .. Test valu 278 Page 11-00/3 ‘00/5 00/5 00/6 00/7 07a 0/10 0/10 00/34 00/12 00/12 0/12 00/13, 00/14 0/14 00/16 0/17 00/20 00/21 00/23 ‘00/25 00/27 11-00/1Connect BMW program tester to 220 volt power .ds and manual remote control Plug adaptor cable No. 61 1 216 into diagnosis, socket on car and connect with program test ccabl on 323i: Romove alr tube. Connect detector clip 1 687 224 529 to eylind Vead and dotoctor clip 1 687 224 530 to igni- tion coil/distributor lead 4, Set range switch to program, ‘Tester is ready for use when yellow indicator iam on Inet check 1amperetuse above mainpower supply cor Set yin selector switch to 6, 270 ? 11-00/3Connect BMW digital tester. Connect test cable with adaptor cable No. 611216. Connect cable for TDC transmitter. Connect trigger clip to cylinder 1 lead as close 1s possible to the distributor. 11-0074‘Switch position U (8 +) 16 volt scale. Check battery voltage’) with consumers off Engine stopped, ignition turned off, 20 O18 ‘Switch position U (15) 16 volt scale Version with breaker points: ‘Turn on ignition at ignition switch. Do not turn ‘on ignition with manual remote control S20 11015 Check voltage?) at ignition coil white operating rler motor. nition: Important: Never workon the contactless tran- sistorized coil ignition system unless the en- gine Is stopped and the ignition switched off. Danger of electric sho Switch on the ignition at the ignition key. Measure voltage’) at coil terminal 1. an 11-00/51) See test values. 11-0076 ‘Switch position U (1) 4.6 volt acal Ignition turned off. Press contact breaker con- trol switch. Green indicator lamp must be on. If not, oper- ate starter motor until green lamp comes on (contact closes). Read voltage drop’). It maximum specifications are exceeded, ‘check contact breaker points and plugs.Switch poston Rr Rrscale ©: © e 1600 1 21 Ignition switched off Remove distributor cap. Detach wire at contact breaker point and wire 1 at plug connector of distributor. Hold wire 1 against ground and adjust needle to lower edge (0) of Rr scale with rotary switch knob Rr. Connect wire 1 to plug connector of distributor. The capacitor is in working order if the reading is within the wide range. Install distributor cap. Important! Capacitor ser the ignition timing. ‘The detect must be found and corrected before adjusting the ignition timing, 27 11-007720k 10 ol Ott ‘Switch position U (D+) 2000 min" scale Set balance switch (8) to 0. Turn distance rotary switch knob (6) to left stop. Adjust image width between O and 100% with rotary switch knobs — (2) and ++ (1) Adjust Image to zero line with knob | (3). Start engine with remote control. Switch on high beam headlights and other electrical consumers if nec ry to prevent su- perimposition of the oscillograph images. Adjust stable rotary switch knob (5) with engine running at speed of 900 min~ until the upper harmonic waves romain constant. Turn rotary switch knob 1 (4) until the upper Important! Only adjust the ima sary. monic wave is about 5 mm (0.2 in). focus (8) and image brightness (7) when absolutely nook Alternator in proper working order. ‘1 O37 Break at one exciter diode. 11-0078 Break at one positive diode, Break at one negative diode.Short circuit at one exciter diode, 20K} row ——} Short circuit at one positive diode, 20K roKv Short circuit at one negative diode, Phase error and short diode. an Irculted negative ° Phase error. 20Kv 10kV ° Diodes with altered characteristic. Important! Deviations below 60% are still ac- ceptable. If deviations are greater than this, the defective diode must be replaced, 11-0078Switch position: dwell Engine speed 2000 min-' 60" dwell angle scale ‘Version with contactless transistorized coll ig- nition: Note: dwell angle is.a fixed design feature and ‘cannot be varied. ‘Check dwell angio ‘at 1500 min"? = 42" 10° at 450mm" =52" + 5°, Basic image EXTERNAL This oscillograph shows the ignition voltage pattern for one cylinder; I the ignition system is, in good working order the ignition voltage peak (1) actually appears on the right screer ‘edge-basic image internal. It is produced at the moment when the contact breaker points, open. Combustion voltage line (2) shows the further progress of the ignition spark, which continues to glow for a brief period. Dying out phase (3) shows how the ignition spark is broken off and dies away. Closing period (4) = dwell angle. ‘The contact breaker points are shut. This is the closed period. All deviations from the basic Image mean faults in ignition system. 11-00/10Version with breaker points: Adjusting dwelt angle ‘Switch off engine. Remove distributor cap, rotor and dust cap. Run engine with starter. langle to 35... 41° by turning the Strive for the smallest value. The value can be read off directly at the digital tester during the adjustment, at starter speed. | 02 we 2° ay the" doe” be” abe abe ezyt Ba os Duell angle 35... 42° Adjust dwell angle to smallest value This oscilograph shows a correctly adjusted dwell angle. Sa 50° 40% 30920" 10° 6 Zyl, 620 1 037 Distributor cam displacement The ignition patterns of all cylinders are superimposed. The distributor cam’s accuracy will determine the regularity of the successive ignition pat- terns. The amount of cam displacement!) can be read off at the scale in degrees. Worn cams, a worn distributor shatt or a loose contact breaker plate will cause alterations in dwell angle and ignition timing intervals, Renew distributor ~ 1211060. 1) See test values 27 11-071120° 42yl.| soe 408308209 10° G Zyl. 620 11038 Dirty and burnt contact breaker points ‘The oscillograph shows this fault by a deformation of the initial dwell phase. Renew contact breaker points. 50° 4g e207 10° 6 zyl eee Contact chatter ‘The contact breaker arm bounces after closing and thus produc: contact breaker points. nother break. Renew - 1o\Kv sor 40° «3020210 Zh ‘600 11 040 Incorrect ignition coll polarity Wires have been confused at ignition coil terminals 15 (+) and 1(-)- Correct the wire connec tions. This refers to the car's wiring and not to the test leads. 11-00/1220° 4ZyL soe oe 30° 20° 10° Gayl 630 1 041 Capacitor series resistance sae rncer series resistance wil cause arcing at the contact breaker point, which turn blue, and the erosion of metal from one contact breaker point to the othce Important: 3 Checking and adjusting ignition timing Requirements for exact ignition timing adjust- ment: 2) Perfect contact breaker points ) Correct dwell angle Detach vacuum hos Start engine, ‘Sot BMW digital toster to 1500 min” with the ‘speed control button +. Refer also to BMW digital tester operating in- structions. Accelerate engine to at least 1500 min-’. Read advance (22° + 0.5') on digital tester. Correction: Loosen distributer mounting screw and correct ignition timing by turning dis- tributor, it distributor. 20 11021 27 11-001311-0714 Centrifugal ignition contro!) (engine at operating temperature) Detach vacuum hosos for advance and retard control. Set BMW digital tester for different speeds (see pages 11-00/19 and 20), and take measurements. Renow distributor it ther from specifications. Is serious deviation Vacuum ignition control 4) Retard control: Install control valve (A) b tween vacuum box and hose (1). Connect the control valve connection (0) with vacuum ‘gauge (In program tester). Detach hose (2) Start engine. Open controi valve slowly ~ vacuum drops. Watch digital tester and road vacuum!) from ‘gauge as soon as the advance angle reading Increases. The value shown on the digital te ter ie the end of the vacuum control, e.g. 3 Open valve further until no vacuum is shown, Watch digital tester and shut control valve slowly. Read value from vacuum gauge as soon as the advance angle drops. The value shown on the digital tester is the beginning of vacuum control, e.g. 24°, b) Advance control: Install control valve (A) between vacuum box and hose (2). Make mea- surement as in point a). ©) Control angle: Measured at end of control a8" ~ measured at beginning of contro! 4) See test values‘Switch position KV Engine 9000 min-* scale 41200...1400min-* rotary switch knob to left stop. view of an ignition system in good cor Only ignition voltage peak of cylinder number 1 I it far right,991109 wing, punow ‘howe oiqeiinsun, MOT sBind eds Aq pouruored (, (\d26 eponoara “elqeidoooe 018 AME oF dn seouasoysia “stopUIAD Ie 20} AyWO}UN 00) aBey0n uontub) “edoosoj}}250 ue yim AY UJ pesnseou wojtu6y Sunsaye sixes 11-00/164zyl 20° 10° 6 Zyl. 630 1 054 insulation test) Gylinder 6 insulation is in good condition. ulling off each spark plug con- Cylinder 5 insulation defective, rector one after the other. — TOK 0° 60° “pe 20° 4 Zyl. T a 50° 40° 30° 20° 10° 6 2yl. on all cylinders Excessive resistance will be noticed when ‘Suppressor resistors between ignition coll), driving the car by way of poor acceleration and istributor or distributor rotor’) with too much inadequate engine power, resistance. Combustion voltage line is at an angle and narrower than usual. +) See test values 2) Warning: Never work on cont torized coll ignition system unle: ‘topped and ignition switched oft. Ds lectrie shock. 270 11-00/17soe 40° 30° 20° 10° 6 Zyl. Faulton one ignition cable, sparkplug connector or suppressor cap. Capacitor Important! Capacitor series resistance willretard the ignition timing. Thi ‘and corrected before timing the ignition. ult mustbe found ‘Turn rotary switch knob — to the right until basic image for cylinder 1 appears separately on the screen. Now turn rotary switch knob «> to the left slowly and check the images in the sequence of the firing order (1-5-3-6-2-4). 11.00/18aor\ 2° 42y T t T 30° 208 10° 67y. 830 i one 1 spark plugs are heavily contaminated, the combustion voltage line will appear thicker than ‘usual and will be superimposed by oscillations. 10\KV soe aoe 10 ¥L 28 080 spark plugs aro severely leaded, the ignition current will stray via the olectically conduc- tive lead deposits when the engine is warm. This in turn will cause misfiring. tolKv 8301 060 Distributor capacitor is shorted to ground it insulation resistance is below 2 K Ohms. Engine will stop running if there is a complete short to ground, an 11-00/192° 4zyl, 1 L T so ae 30? T 20° 10° 6 2yl. 630 7 061 Short in ignition coil primary winding ‘Turn back rotary switch knobs —- and —- to thelr initial positions (cylinders 1...6 between 0 and 60°). 9000 min* scale Engine speed approx. 1200,..1400min" lo Ky 80° 49° op s0° aoe 302209 20° 42yl. 10° 62yl 8201 06 ‘The ignition patterns of all cylinders are superimposed for comparison with each other. 4Zyl 50° 40° T 30° 20° 10° 6 Zyl. ‘This oscillograph shows that a suppressor resistor for one cylinder Is defective. 11-00/20an ‘Set balance switch to 0. ‘Turn distance rotary switch knob to the right until all cylinders appear on the screen. The cylinder patterns are superimposed in sequence of firing 0° 40° Excessive suppressor resistance at cylinds 11-00/21‘Switch position balance 2000 min’ scale Engine speed 1500 min~* Power output comparison of cylinders Important! This test requires perfect carburetor, ignition tim- ing and valve clearance setting: ‘Adjust cylinders with selector switch (B) one after the other in sequence of firing order, and short circuit each cylinder by pressing button (A). Read speed drop on scale. Speed drops should be as uniform as possible and about 100 min * per cy- linder. Check compression it speed drop Is lower than this. 11-00/22‘Switch position Hem tested Specification min. 11.8 volts min, 10.8 volts ’b) While starting ‘min. 9.0 volts Voltage op at contact breakere and plug Capacitor series resistance ‘Alternator ‘) Voltage at D+ 'b) Checked with oscillograph at 900 min‘) 3 volts within Rr range 13.5... 146 volts, ‘see page 11-00/7 35...41° 2.0.35 mm (0.014 in) | max. 3° ‘Centrifugal control without vacuum c | min [ 7000 1500 Verst ‘Aimed at TOC mark 2000 vs x Digital 2500 | Tester 3000 aae Distributor No.: 0 231:309 007 3500 37° (end) Digital Vacuum control Begins ‘Advance 110... 140 Retard 50... 60 nore mm/Hg_ Ends ‘Advance 175... 185 Retard 92... 105 Control range at crankshaft ‘Advance 8°... 12° Retard 8°... 12° 150-200 min so iw aKV Bal 160% Exhaust test at 850 © 60 min Fuel pump pressure2yo0ys a499I0 1818} jo 196ueq “yo pousiims uo}uBy pue paddoys s} ousBue ssejun weysAs uopu6} 100 pezLo}sIeUEN} 880726}U0 UO BUOP 04 0} 10m OU :BUlUIE/H (, uy al zy "** 82) (peyoeiep sorejnBes eansseid 0} os0y wnnoeA) ounssoid duind jon “LUN 0S = 006 18 181 suo|seIWe yeneura iCal aiqissod se wioj1un se 9q isn spacds 6uiuuny, {UR 900 1 18 INdino Jemod sepuUt|fo Jo wosHHEdWOD 1a Ag uw | ((ayowep sdeo Gnid s1eds) @Bejon peol-Ho 1109 pousdo sj omen voum esee10u, - ‘Siepunio ueemjeg oBeh]0n wontuB v! uoNEHEA lu Oop" 00zL ve eBeHOR uoRIUB) | a a vequi obs **osb piBies vequi 062" OPt prevos "0b eoueape suiBeq joxu09 uonu6} wnnoen 42801 1611510 0008 ‘900208 £820 °ON ZoINqUAIC cove ‘ost edb ath ‘008 494804 124610 aia 9. a (jones vopus win yonluo uo nub B11, ‘D014 ze Tonos wnnaea ynouuN , Uius 005 LB WORIUBL 291801 [2610 «8 F.28 00s pan COL F ste ost _umuye aiSue tema ‘ 00-1) 268d 208 {Una 908 98 1883 edoasomsO (4 Aovi-seL + aie aber104 ( soveUsouy (an Roz moiea 91 [eujuuay yun jonuod 30 4 jeuruer 1109 we SBE NOR Wa A06 UI Gumers Guunp (@ Ago “UME quauin9 1109 peol-yo (e | a Se _ St reutuzor 109 18 eB eon | jon Agu un Srewnsu0 ynoyym oBei10n Kone Gan parser won, wontsod youns 1 €ZE MING — 182) WesBoldAdditional test Voltage resistance and capacitance tests can also be made with the test lead via the range switch. These tests can be made at any program switch position; this will not impede the other programs ~ except the voltmeter. Voltage test Set range switch to X 1 V or X 0.1 V depen on test range. ‘Test lead connection red clip to+ black clip to— Capacitance test Sot range switch at X 1) F or X0.1 « F depend- Ing on test range. 620 1 069) Important! For capacitance tests never short circuit or supply voltage to test terminals. Built-in capacitors must be disconnected before testing. Connect capacitor between clips of test lead. Read test value!) on instrument. Note! Capacitors which were not used for a long time or are new must be charged and dis- charged betore testing. Otherwise the series resistance shown will be too high, but will dis. appear immediately after being put in operation. 4) See test values. 2am 11-00/25Resistance test h, Sot range switch at X 1 Ohm or X 1 KOhm de- «ux Pending on test range. GZ Calibrate the applica t © test. Short circuit test terminals. _4, Selnecdle of instrument at 0 (bottom scale) with rotary switch knob for Ohms (2). . Dy st range before each Connect resistor’) between clips of test lead and read amount of resistance. The degree of insulation is better, the higher ince. Normally the instru- range X 1KOhm will deflect completely when insulation is perfect, Le. infi- nite resistance. Important! Never supply voltage to test terminals. 0.25 ampere fuse on front of tester, right-hand, sid 1) Soe test values 11-0028,‘wuoM o0z 18801 18 av azo" a0 4.99 °**) 9,02 ** +18 sony gz F WOM vb pSz © WON L hse = wow s Tope0u09 Bd deo soinquisip w deo sossesdcng SGnjd pue siayeaiq j2eU09 18 dosp s6ei10A Sunes ou (@ uonwuBl iy (e Sh [Buju 1109 WOIUBI Je aBEHOA oy nd SNOAzZLISeOI IY son uonpucs 26ey]0n pai ‘eBieuD = ‘uonipuce @612u9, 389} UORIPPe 10} Senjen so, 11-0727 an11.00 039 Compression test on all cylinders On 323i only: To prevent the cylinders from becoming flooded with fuel by the injectors delivering fuel continuously as the starter is run, the fuel Pump relay (1) or diode relay (2) must be re- moved. Remove the spark plugs. ‘Check compression’). 11.00 050 Engine — removing and installing Remove gearbox ~ 23 00 020 or automatic transmission ~ 24 00 020. Take off the engine compartment lid — 4161 000. Remove the air cleaner - 1371 000. Remove the radiator ~ 17 11 000. Remove the coolant equalizing tank. 2311102 Detach the positive and negative leads from the battery. Take off cable (1), 1) See specications [2011 100 27 11.00/2811-00/30 Carburetor engine: Detach fuel hoses (2) and (3). When installing: do not accidentally confuse these hoses. Hose (2): fuel supply; hose (3): fuel return. Unsorew nuts (4) and disconnect the acy celerator cable. When installing: adjust the accelerator cable~ see 35 41 421. Detach coolant hoses (5) and (6). Disconnect vacuum hose (7). Fuel injection engi ‘Take off the intake alr scoop. Detach injector lines (1... 6). Detach fuel lines (7) and (8). When installing: do not accidentally confuse these lines. (7) to cold-start valve, line (8) to warm- ing-up sensor. Check condition of sealing rings and renew if necessary. Re holder (9).Detach fuel lines (10... 12). When installing: tine (10) to warming-up sen- sor, line (11): fuel supply, line (12): fuel return. Loosen nuts and take the mixture regulator with air cleaner housing out upwards. When installing: the rubber underlay mustbein MRI the funnel on the air cleaner housing. Detach the accelerator cable and from the reaction bearing. When installing: adjust accelerator cable—see 35.41 421, Detach coolant hoses and vacuum hose. jaa HNO 2m 11-00/31Pull off the protective cap. Pull out plug (1). Pull off leads (2. ..4) When installing: black/red and gr ‘Ohm black/red to 0.6 Ohm n to 0.8 Lift the wiring harness out of Its clip on the wheel arch. Suspend the engine from engine lifting beam 11.0020 at front and rear. 11-00/32Detach earth (ground) strap(5) and left engine mounting. Detach right engine mounting. Raise the engine and ltt out towards the front. an 11-00/33Sectional view of fuel injection engine27 1111 160 Distributor shaft bearing — re- newing Remove oil pump ~ 11 41 000, Remove distributor — 12 11 060. Remove needle bearing by driving it out from bottom to top with special tool 111.310. When instalting: Lubricate needle bearing, Drive in needle bearing up to stop with special tool 11 1.300, 62011205, neat11 12.000 Rocker cover ~ removing and installing Remove the air cleaner — 13 71 000. Slacken nuts (1... 6). Warning: take off spring washers. Take off the rocker cover. When installing: tighten nuts in the order 1 10 8 shown. Check condition of gasket and ary. 11 12 100 Cylinder head — removing and installing Detach exhaust pipes from exhaust manifolds. Detach the exhaust pipe support. When Installing: install exhaust pipe support without trapped str Remove rocker cove Drain the coolant. When installing: bleed the cooling system — 17 00 039, Disconnect the negative lead from the battery. Carburetor engine: Detach coolant hoses (1... 3). Detach leads (4) and (5). Detach fuel hoses (6) and (7). When installing: do not accidentally contus these hoses. Hose (6): from fuel pump Hose (7): to tank Detach leads (8) and (9). When instating reen/viclet lead to servo motor ‘green/black lead to choke housing Disconnect the accelerator cable and remove from reaction bearing. When installing: adjust accelerator cable — 35.41 421, an 1112/1Pull off vacuum hoses (10 and 11). Detach lead from heat-sensitive switch. Detach coolant hoses (12 and 13). Detach the plugs from the idle shutoff valves. Detach the vacuum hose (14) and coolant hose (5). Unscrew nuts (1). Disconnect the throttle position cable. When installing: adjust the throttle position ca- ble ~ see 2400 004. 14-1272Unscrew nuts (1) and pull throttie cable out downwards through the hole in the int ‘Take off the air intake scoop. Disconnect the accelerator cable and remove from its reaction bearing. When installing: adjust the accelerator cable — 35.41 421. Detach injector pipes 1 ... 6 from the mixture regulator. ‘Check condition of sealing rings and renew if necessary. Detach fuel line (7). Take off holder (8) 278 14-1278Detach hoses (9) and (10). Lift hoses away from clips. Pull off vacuum hoses. Pull plug away from cold-start valve and from ‘additional alr slide. Detach coolant hoses (12) and (13). Detach vacuum hose from air collector. Detach coolant hoses from branch flange. Pull off plug and lead. eae ni27 Detach the spark plug caps. Take off the distributor cap. Detach the ignition lead. ana2aRemove bolt (1). Take off belt pulley. Take off V-belt. When installing: adjust V-belt to correct ten- sion. It should be possible to depress the V-belt by 5 . 10 mm (0.2...0.4 in) atthe center of its run. Lift the position indicator out of its clip. When installing: check that position indicators correctly located. Gap between position indicator and vibration A=0.2... 2.0 mm (0.008 ... 0.08 in). Detach the vibration damper from its hub. Warning: engine mustnotbe turned over atthe adapter unless the spark plugs have been moved. Set the piston in cylinder 1 to TDC, so that the engine speed governor is aligned with the notch in the distributor body. Remove the protective cover. When installing: attach the suspension eye (2) at the same time, Loosen bolts (13) and (14). Press the tensioning pulley inwards, Tighten bolt (13). ‘i on 12/511-1216 Take toothed belt off camshaft sprocket Important: Engine must not be turned without the toothed belt. When installing: Check TDC position of crank- shaft, camshaft and position of distributor. Tighten toothed belt ~ 11 31 100. Check toothed belt and renew if necessary — 1131110, Press down balance tube and lock with special tool 11 1 290. When installing: Check seals and renew if necessary. ‘Take off cylinder head. When installing: Tighten bolts in sequence 1... 14 one after the other in three steps’). Run engine to operating temperature. After, test run, let engine cool down to 35°C (95°F). Tighten cylinder head bolts to final torque. ‘After driving a distance of 1000 km (600 miles) the cylinder head bolts have tobe retightened. Important! There must not be any oll in the ‘cavities, since otherwise the bolts will not give {ull pressure on the cylinder head in spite of being tightened to the proper torque. Furthermore the crankcase could crack. When installing: Clean cylinder head bolts and lubricate threads lightly with oll. The cylinder hoad gasket must always be renewed Adjust valve clearance ~ 11 34.004. ‘Adjust engine Idle speed/test CO level - 13.00 054, +) See specifications11 12 101 Cylinder head gasket ~ renew- ing Remove cylinder head Clean sealing surfaces on cylinder head and crankcase thoroughly. When installing: Use only original cylinder head 9 ince the coolant openings have to be exact. When installing: Mt necessary, grind cylinder head sealing surface 11 12719. 14.12 100. 11 12.240 Radial seal in timing case cover = renewing Remove toothed belt ~ 1131110. Take off adaptor. Take toothed belt whee! off camshaft. When installing: Cylindrical pin (1) must fit in hole in toothed belt wheel. Note correct tightening torque?) Take off guide cover. Replace radial seal and round cord seal. 1) See specifications ara 0117 fer 18138 1112/71112/8 When installing: Us stall the guide cover pecial tool 11 2 212toin- 1112 561 One valve guide — renewing — valve removed — Drive out vaive guide in cold state with special tool 11 1 330 into combustion chamber. A has been exceeded, ream out the bore and install an oversize") valve guide. Heat cylinder head’), Drive valve guide into combustion chamber from camshaft end with special tool 11 1 320. Stepped end of valve guide faces camshaft. Important: Bore in special tool determines the installed depth B of 14.5 0.5 mm (0.571 * 0,020 in). Ream out valve guide to diameter 7H7. 4) See specifications1112607 Valve seats and valves — machining ~ cylinder head disassembled Note minimum edge thickness A) and valve ‘seat angle B. Valve must be replaced when edge thickness is below specification. Machined valve marks. Bed in valves with grinding paste. When installing: Check valves for leaks — 1134809. must not have chatter 1112719 Cylinder head sealing surface — refacing ~ cylinder head disassembled — When machining the cylinder head sealing surface not more than 0.3 mm (0.012 in) must ‘be removed from the total cylinder head origi- nal thickness A of 125.1 0.1 mm (4.925 + 0.004 in). Important: Use stronger sealing at retaced cylinder head. 1112729 Cylinder head water leak test — cylinder head disassembled - lls 111.021 on to cylinder head (use Mla 111023 Plug water circuit on cylinder head with sealing platos 11 1.023, 11 1024 and 11 1 025. 1) See specifications son ms. a7 1112/9Pump compressed air into cylinder head. Test pressure 1.5 bar (21 Ib/in’). Place cylinder head in a water bath and check for cracks. sao 13448 viet2sto Teas11.13 000 Oil sump — removing and ling Remove guard. Drain oil. Take off sump, Titt down sump. Remove pressure @. Remove oil sump t When installing: us lof valve (1) and oll pump ids front. new gasket. When installing: Cl ling surf Coat mating surfaces on timing cas end cover with Atmosit or Curll K2. 0 11 150 208 1911 14 175 Front end cover—removing and installing radiator ~ 17 11 000. Remove V-belt, When installing: tension V-belt correctly. The V-belt must yield by 5...10 mm (0.2...0.8 In) when pressed in at the center of its run. Extract the position indicator from its clip. When installing: check that position indicators, correctly located, Gap between position ing ccator and vibration damper (0.008 ... 0.08 in). Detach vibration damper from hub. When installing: centering pin (2) must be in hole on vibration damper. Prevent hub from turning with retainer 112150. Unscrew bolt (3) Take off shouldered disc (4). Insert bolt (3) by approx. 3 turns. Pull off hub with Kukko puller 007.501 and threaded spindles 112 132 from crankshaft. Remove bolt (3). 1) For correct tightening torque, see Specitica- tions.a4 ‘Take off the toothed belt — 11 31 110. Insert bolt (3) again. . Detach sprocket from crankshaft with Kukko puller 00 7 501 used in conjunction with threa- ded spindle 112131. Important: note shaft key. When installing: mount the sprocket with the tapped holes facing out. Use special tool 11 2 190 to prevent the inte mediate shaft sprocket from turning. Remove bolt (6)'). Take off the wash ind the sprocket. When installing: the centering pin (7) must en- ter the hole on the intermediate shaft. Remove bolts (8 ... 10). smaining oll sump bolts should only be When installing: use a new ga If the oll sump gasket becomes damags tach the sump and renew the gasket — 1413 000.(Check condition of radial sealing rings and re- new if necessary. Warning: install only with sleeves 11 2211 for ‘crankshaft and 11 2 212:for intermediate shatt. 11 14180 Radial sealing rings in end co- ver — renewing Remove the end cover ~ 11 14175. Press the radial sealing rings out of the cover. Drive in radial sealing rings with sleeve 241 050 for crankshaft or drift 331180 and handle 00 5 500 for intermediate shatt. ‘Sealing rings must be driven in until flust Pack sealing lips with gre 1114611 Radial sealing ring in clutch end cover ~ renewing ~ flywheel removed — Remove the bolts at the oil sump — end cover. Only detach the the oll sump gasket is damage oll sump — 11 13 000. Renew gasket (1 Warning: check that the sealing cover (2) for the main oll passage is not leaking, and renew sealing plug (3) it necessary. Apply Loctite No.270 to sealing plug before in- serting. 270 poz. 0132 1114/3Tear 820 11 218 Press in the radial sealing ring, with driving ‘sleeve 111260 in conjunction with handle 005 500, Pack the sealing lips with great Coat the joint line betwoen the end cov. oll sump with ‘Atmosit’ or ‘Curil K 2. To prevent damage to the radial sealing ring, use slipover bushing 11 2 213,1121 000 Crankshaft ~ removing and in- alling Remove engine — 11 00 050. ‘Secure crankcase to assembly stand 00 1 500 with assembly plate 110120, 20 19 151 Detach the clutch - 21 21 000. Detach the cylinder head - 11 12 100. Remove the front end cover ~ 11 14 175, Detach the oil pump ~ 11 41 000. Before removing the crankshaft, determine its ‘endplay (axial play)'). Hf maximum endplay is exceeded, check the locating bearing. 20 1152 Rernove the flywheel! — 11 22 000. Detach the ond cover. When installing: Apply a coat of ‘Atmosit’ or “‘Curll K2'to the joint line where the end cover ‘meets the oil sump. Install the big end bearing caps in the bottom dead center position. When installing: the connecting rod and bearing cap for each cylinder are marked. Con- ecting rod 1is at the toothed belt end. The cy- linder reference numbers must all be on the ‘same side. 4) See specitications oes an wat11.2172 20 11168 Note when installing: do not re-use old big end bolts. Tighten the bolts to the specified tor- que!). Afterthis, turn the bolts through a further 70° with special tool 112 110. Tab off the main bearing caps. Lift out the crankshatt. When installing: do not accidentally confuse the bearing caps. Bearing cap 1 Is at the toothed belt end. the crankshaft, use one red and one blue be- aring shell for each bearing journal. that all blue or all rad bearing s elther at the top or the bottom. When installing: the grooves in the main bearing caps must coincide. 1121501 Crankshaft - renewing — crankshaft removed ~ Transfer the needle roller race to the new ‘crankshaft ~ 11 21 571 Crankshaft identificatio ‘Standard grinding dimensions: one red or blue aint spot at side of counterweights. +) See speciticationsReground crankshatts ar stripes. Big end bearing journal (A) — 1 paint stripe: undersize 1") ~ 2 paint stripes: undersize 2!) Main bering journal (8) 1 paint stripe: undersize 11) ~ 2 paint stripes: undersize 2!) Warning: the crankshaft is “Tenifer’ treated ‘and can only be reground at the factory. marked with paint Install the correct bearing shells to suit the bearing journal diameters now in use; the Same red or blue color codes must appear on the bearing shells as on the crankshaft. If the crankcase has a different color coding from the crankshatt, use one red and one blue bearing shell per bearing journal. Red and biue bearing shells are supplied with replacement crankshatts, When installing: make sure that either all blue or all red bearing shells are installed at the top or at the bottom. ‘1 Main bearing shell 2 Locating bearing shell Check bearing play’) with ‘Plastigage’ Type Pat. 1) Measure each bearing separately. b) Bearing surfaces must be oil-dry. ©) Measure with crankshaft at top dead cen- ter. 4) Tighten bearing cap to specitied torque’), €) Do not turn the crankshaft during the mea- suring procedure. 1) Read off b ing play!) by comparing the width of the compressed area of plastic strip with the scale, ‘Plastigage’ is supplied in three ditt moti sstigage’ supplier: ERN Co., Schinkelstr. 46-48, 4000 Disseldort. 1) See specifications 270 20 11 10 11-208a2ta 1121571 Needle roller race in crankshatt mnewing — clutch removed = Remove needle roller bearing from crankshaft with puller 112070. When installing: inscription on needle roller bearing should face out. Drive in the needle roller race with a suitable arbor. Keep to dimension A= mm (0.2 in). Pack the needle roller race with a brand-name ‘multipurpose grease.11 22.000 Flywheel — removing and instal- ling Remove the clutch ~ 21 21 000. Check the flywheel for axial runout’). Prevent the flywheel from turning with holder 412170. Remove the expansion bolts. ‘Important: when installing, use new expansion bolts and apply Loctite No.270 to them before inserting Take off the flywheel, When installing: the clutch friction surface may be skimmed if not flat. However, the wall thickness within the rubbed ‘must not drop below 13.5mm (0.531 in) 11 22.051 Torque converter driving plate — renewing Remove the transmission ~ 24 00 020, Prevent the flywheel from turning with holder 192170. Remove the expansion bolts. Important: when installing, use new expansion bolts and apply Loctite No.270 to them before inserting. Renew the driving plate, 1) S00 specifications 201 242 27 22111-222 11 22541 Starter gear ring ~ renewing ‘To simplify removal of the gear ring, drill into it below atooth gap tora depth of app. 8mm (0.31 In) with a 6mm bit. Split the gear ring by striking with a cold chisel in the tooth gap above the drilled hole. When installing: heat the new starter gear ring to 200... 230°C (392.... 445°F), using a thermo- chrome pin. The chamfered side of the gear teeth faces the engine. Drive the gearring fully home with a brass drit.14 24821 Allconnecting rods—renewing— pistons detached — Warning: the connecting rods in any engine ‘must all be of the same weight group, with a to- tal weight tolerance of = 49 (0.141 02) without the bearing shells. The weight group Is shown by a color code. if no color code is visible, a second connecting od must be removed and the weights compa red. Warning: connecting rods must notbe retaced: sm 11166 ‘The piston pin!) should slide through the ‘small-end bearing bushing when only light pressure is applied. ‘Check connecting rod for deviation trom p {el (A) and permissible maximum twist (8), and te-align if necessary. ‘4.150 ~0.04 mm (5.055 ~0.0016 in) Bo" -30 aad eon Install big end bearing shells in connecting rod, Place ‘Plastigage PG 1° on oil-free big end bearing journal, Attach connection rod to crankshatt. Note identification marks used to match con- necting rod and big end bearing cap. +) For piston pin running ct tions ance, see Specitica- 2m 1-24/114-2472 ‘To measure bearing play, use old big end bearing bolts. Tighten the bearing cap to the specified tor- que'). Warning: do not twist the connecting rod or the crankshat Take off the bearing cap. Compare the width of the co Strip with the calibrated s bearing play’) “Plastigage’ supplier ERN Company, Schinkelstr. 46~48, 4000 Dis seldort, Federal Republic of Germany. 1) See specifications1125 000 All pistons ~ removing and in- stalling Detach cylinder head ~ 11 12 100. Remove oll pump ~ 11 41 000. Detach big end bearing caps in bottom dead center position, When installing: the connecting rod and bearing cap for each cylinder are mark: Connecting rod 1 Is at the toothed belt end. The cylinder reference numbers must always be on the same side when installed. Important: use new big end bolts when instal- ling, Tighten bolts to specified torque’), After this, tighten bolts by a further 70° with special too! 172110, Press the piston and connecting rod out up- wards. When installing: stagger the piston ring gaps. by 120°. ‘The arrow on the piston crown must face the toothed belt. Mark the correct relative positions of connec- ting rod and piston. Extract snap ring (1). Remove piston pin. When installing: piston pin and piston are mat- ched and must not be interchanged. £ ae sme make ~ 1 Warning: install only pistons of th and weight group in the engi ‘The weight group Is indicated by a + or ~ stamped on the piston crown. 1) See specites fons som 27 14-25/120/92 Distinguishing features of piston: BMW" | Piston Piston "Identiication model | diameter crown mark on piston a [crown © m0 | comm [21mm la | 380 i) (0.927 i) 9201 | 80mm fiat aves iy | Check piston installed clearance’). BMW Pieton model _ make © mm (0.354 in) 320 | Mahle KS 25.95 mm (1.022 in) 3231 | Mahle | 12mm (0.472 in) | ks 28.05 mm (1.104 in) so i73 Set internal dial gauge to zero with the micro- at the measured piston diameter. son mM the center with the internal dial gauge. Deter- fe the cylinder bore at 3 points across mine piston installed clearance. aires 1) Se 11-257211 25 651 Piston rings for one piston —re- 7 newing ~ piston removed - ‘Measure clearance’) at ring flanks. Remove piston rings and measure end gap! so 74 installing: “TOP marking must be piston crown when piston ring Is in- stalled. 1 Rectangular-section ring 2 Micro-chamfor ring 9 Slotted oil-control ring with tubular spring TOP. 329 1152 ') See specifications: 20 11-257311.31 000 Camshatt—removing and instal- ling Remove rocker shafts ~ 11 33 020, off locating cor When installing: check condition of ing ring (1) and cord ring se ary. When installing: use bushing 11 2 212 to install locating cover. Pull out the camshatt 1131 100 Toothead belt - tensioning Unscrew bolts (1) to (3). fa 877 ar 31Warning: do not turn the engine over at the adapter unless the spark plugs have been re- moved. Using a '/," ratchet, turn the engine through 1... 2turns at the adapter, in the opposite di- rection to normal rotation. This will tension the toothed belt. {In this position, retighten bolts (2, 3 and 1). 1131 110 Toothed belt ~ removing and in- stalling Drain the cooling system. When installing: bleed the cooling system ~ 1700 039. Detach the hot water hoses (1 and 2) Detach holder (3). ‘Take out bolt (4). ‘Take off the belt pulley. ‘Take off the V-belt. When installing: adjust V-belt to correct ten- It should be possible to depress the V-belt by 5...10mm(0.2...0.4in) atthe center ofits run. Lift position indicator (5) out of its clip. When installing: make sure that the position indicator is correctly located. Gap between position indicator and vibration damper A 0.08 in). Detach the vibration damper from its hub. When installing: centering pin (6) must local the hole on the vibration damper. fsa) 10181 11-312Detach protective cover, When installing: de net forget to attach tug plate (2). 529, 11120 Warning: the engine must only be turned over atthe adapter after the spark plugs have be removed. Set the piston in cylinder 1 to top dead center. The arrow on the camshaft sprocket must be aligned with the mark on the eylinder head; the mark on the crankshaft hub must bi with the mark on the end cover. 20 11189 Mark the running direction of the toothed belt. Remove bolts (8) and (9). Press the tensioning pulley inwards. Tighten In. Take off the toothed Warning: the engine must notbe turned over at all when the toothed belt has been removed. When installing: before placing the toothed bbelt on its sprockets, check the setting at the distributor housing. ‘Take off the distributor ‘The notch in the distributor housing must be aligned with the center of the engine speed governor. S210 188 1131/311-3174 520.11 187 Arrangement of toothed belt: 1 Camshaft sprocket 2 Tensioning pulley 3 Crankshatt sprocket 4 Intermediate shaft sprocket 5 Toothed belt Examine the toothed belt for signs of damage, and renew if necessary. Starting at the crankshaft sprocket and wor ing in the opposite direction to engine rotation, place the toothed belt over all its sprockets. Release bolt (8) again. ns of a '/z inch ratchet turns in the oppo- site direction to normal rotation. This will te sion the toothed belt correctly. In this position, tighten bolts (8) and (9). Check the aligment of the crankshaft and cam- shaft marks again. Rotime the ignition — 12 11 004,11 33.020 Rocker shafts ~ removing and installing 1 Remove cylinder head — 11 12100. Mount cylinder head on assembly fixture 111060 and secure with one cylinder head bolt. Detach oll tine (1). ‘Take off the toothed belt Set valve clearances for all cylinders to max- imum, Extract sealing plug. Remave locating plate (2). When installing: locating plate (2) ‘must be in the grooves of the rocker shatts. em 11234 Remove the spring clips. When installing: the straight tace on the spring clip must be in the groove cn the rocker shat To turn the camshaft, attach washer (3) and aciapter (4) to it 2m 11-83/1‘say 22 20 14.230 11-33/2 Remove the rock a) Exhaust side Cylinder 6 must have the valve Push the rocker for the first cylinder inwards. Turn the cams the adapter towards the Inlet side until all the rockers are no longer un- der spring pressure. Pull out the rocker shat shatts. ‘on overlap, b) Inlet side Pull out the rocker shart. Renew rocker shatts and rockers if worn or When installing: the large oll holes on the rocker shafts must face the valve guide and the grooves for the locating plate must face inwards. 1133031 All rockers ~ renewing Remove rocker shafts ~ 11.93 020. Renew rockers which are worn, scoredorhave loose pads. Loose pads will be audible in the form of ex- cessive valve 9}‘Transfer setscrew (1), eccentric 2), washer (3) ‘and nut (4) to new rocker arm. Replace worn eccentrics. Important: Setscrew and nut have M 8X 0.75 mm fine threads, Hole faces outward and thick side downward, Bovolled side of setscrew faces tab on rocker arm. a01134 004 Valve clearances ~ adjusting Remove cylinder head cover — 11 12 000, Warning: engine must only be turned over at adaptor after removing spark plug Turn engine with a '/,"ratchet applied to adap- tor. Adjusting sequence is same as firing order (1-5-9-6-2-4) at compression to dead center (roo). Adjust valve clearance!) between valve and eccentric after loosening nut (1) Tighten nut (1) with special ring spanner 111 150 and torque wrench 00 2 050. Note correct torque’) 11 34 509 All valves — checking for leaks — camshaft removed — Spark plugs remain installed. Fill combustion c! th gas Valves have to sd when gasoline runs past valve head (see 11 12 607). 11 34 550 Valves~removing and installing = rocker shafts removed — Place tray 11 1066 in assembly stand 11 1 060. 4) See specitications 520 11295, 27 113471Press down valve springs with special tool 111060 and remove valve collets, Remove upper spring retainer, spring and lower rotaine When installing: Relaxed spring length A’, ‘Important: Valve spring is wound progressiv. y. End with tight winding (paint mark fac der head. Pull out vaive, When installing: Lubricate valve guide and valve stom with oll. Install valve. Always use ai damage to valv: Lubricate and install vaiv ‘Supply source for assembly sleevi Cartool Unterer Grasweg 10-8070 Ingolstadt West Germany smbly sleeve (2) to prevent Press on valve seal with special tool 111 140, until a tight fit 4) See specttications 11-347211 36 020 Distributor intermediate shaft — removing and installing Remove front end cover ~ 11 14175, Detach guide plate (1). Pull out intermediate shat (2) 14-35/11141 000 Oil pur.ip ~ removing and instal- ling Remove oil sump ~ 11 13 000. Take off oil pump. When installing: Guide input shaft (1) into dis~ tributor shatt. \ 11 41 110 Pressure relief valve — removing and installing Remove oil sump Unscrew pressu: Remove outer tube (1). Unscrew plug (2). Remove spring (3) and piston (4). Importar‘t! Relaxed spring length’) must not be altered. +) See specitiations sao 11192 27° Wait11 51000 Water pump ~ removing and in- stalling Drain coolant. When installing: bleed cooling system — 47 00039. Detach belt pulley. Unscrew bolt (1). Take off V-belt. When installing: Tension V-belt Take vibration damper off hub. When installing: centering pin (2) must be in hole in vibration damper. Loosen warm water hose (3), remove hose (4) and take off holder (5). Remove position indicator (6) trom mounting. When installing: correct seating of position in- dicator. Gap between indicator and vibration damper must be 0.2... 2.0mm (0, . smove cover. When installing: Also attach suspension eye m. Hold clamping pin with special tool 115 010. Strong spring pressure! 2m sD 10198 1151/1Looren warm water hose (8). Take off water pump. new gasket. Important: check Passage is not! at end cover (9) of main oll king; install a new plug (70) if Insert plug with Loctite Ref. No.270. 11.51 502 Water pump ~ stripping and as- sembling ~ water pump removed — Pull off huo with special too! 00 8 500 (Kukko). 520 11198 When installing: Distance A=4.1 +0.3mm (0.161 + 0.012 in. 11-5172Remove cirelip (2). Press impeller off shaft and water pump bear- ing out of body. Renew bearing (3) and seal (4). Check impeller (6) and renew it necessary. When installing: Long shatt of bearing (3) faces Impelter. 20 11 202 When installing: Press on impeller. Distance B =0.6 :0.2m.a (0.024 + 0.008 in) must be observed. Pross-in force approx. 4440 kp (9701b); for new parts 500 kp (1100 Ib). 20 11203 an 11-51311814 Water pump layout Hub 2Circtip ‘3 Pump bearing 4Seal 5 Cover ring S impeller 7 Body1153 000 Coolant thermostat ~ removing and installing Partially drain coolant. When installing: bleed cooling system — 170038, ‘Take off cover. Remove thermostat. Check begining of thermostt opening) in a hot water bath. When instaling: bracket on thermostat faces out 1153 081 Temperature sensor —renewing Disconnect wire from sensor. Unscrew sensor. Replace seal (1). When installing: bleed cooling system — 17 00039, 9) See spenitnanans ast an1161000 Intake pipe and carburetor — removing and installing/sealing Disconnect negative lead at battery. Detach air cleaner 13.71 000. Drain coolant. When installing: bleed cooling system — ! 1700 039, Detach supply (1) and return (2) fuel ines, Detach preheating hose (3). Disconnect cables (4) and (5). When installing: green/viclet cable to control motor green/black cable to cold-start housing Detach carburetor control Detach water hose (6). Detach hoses (7) and (8) and remove by pulling down. Wher installing: adjust accelerator cable — 35.41 421, Detach black vacuum hose at distributor and wires at thermo switch. Pull off plug for idle cut-off valves. Detach hoses (9 to 11),(On automatic transmission cars: Unscrew nuts (1). Disconnect accelerator cable. When installing: adjust acc 24 00 004). tor cable (see Unscrew nuts (1) and pull accelerator cable ‘out downwards through hole in intake mani- fold, Press down balance tube andlock with specie tool 111.290. e211 125 Detach intake manifold at cylinder head. When installing: use new gaskets. Note instal- led position of gaskets. eos 11-61721161050 Intake air collector ~ removing and installing Disconnect negative lead at battery. the cooling system, Detach accelerator cable and remove trom reaction bearing, When installing: adjust accelerator cable — 3541421, Detach hoses (2 and 3). Pull off vacuum hose (4). Pull off vacuum hose (6). Detach hose (7) Detach hose (8) at branch flange. ull off plugs (9) and (10). Detach fuel tine (11). an 11-8113‘Take off vacuum hose (12). Detach holder at air collector. ° Detach injector pipes (1... 6). Press equalizing pipe down and hold with spe- cial tool 11 1 230. Detach air collector from cylinder head. 11-6174When installing: renew gaskets and ensure they are correctly positioned. Renew sealing ring (13) 1161051 Intake air collector ~ renewing Remove the air collector ~ 11 61 050. Transfer the throttle butterfly stub pipe (1), cold-start valve (2), holder (9) and additional air slide (4) to the new alr collector. Transfer injectors 1....6. Renew sealing rings (5) and coat with Vaseline or similar before installing. 2329-11150 an 11-6151174051 Thermo valve ~ renewing ich hose (1) at thermo valve, 30 (2) at distributor and blow through mo valve must be closed at coolant tem- Peratures up to + 13 + 3°C (55 =6°F)and open from +20: 9°C (+68° + 6°F). Unscrew thermo valve, ‘Add coolant. Important: Only install thermo valves with de: Ignation PE 20 286 yellow or §1 AB 12biue with 2 yellow spot. an wera