BMW 1989-1995 525i User manual

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Bentley Publishers

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Foreword v
Warnings and Cautions vii
Index back of book
GeneralData and
Maintenance 010 Fundamentals for the Do-it-yourself Owner
020 Maintenance Program
Engine
Transmission
Suspension,
Steering and
Brakes
Body
Body Equipment
Electrical System
Equipment and
Accessories
Electrical Wiring
Diagrams
100 En gi n~ eneral
110 Engine Removal and Installation
113 Cylinder Head Removal
and Installation
116 Cylinder Headand Valvetrain
117 Camshaft Timing Chain
118 Camshaft Timing Belt
200 Transmission-General
210 Clutch
230 Manual Transmission
300 Suspension, Steering and
Brakes-General
310 Front Suspension
320 Steering and Wheel Alignment
400
Body-General
410 Fenders, Engine Hood
510 Exterior Trim, Bumpers
512 Door Windows
513 Interior Trim
600 Electrical System
-General
610 Fuses and Relays
611 Wipers and Washers
612 SwitchesandElectrical Accessories
720 Seat Belts
721 Airbag System (SRS)
119 Lubrication System
120 Ignition System
-DM E
121 Battery,Starter,Alternator
130 Fuellnject
ion- DME
160 Fuel Tank and Fuel Pump
170 Radiator and Cooling System
180 Exhaust System
240 AutomaticTransmission
250 Gearshift Linkage
260 Driveshaft
330 Rear Suspension
331 Final Drive
340 Brakes
411 Doors
412 Trunklid,Tailgate
515 Central Locking
520 Seats
540 Sunroof
620 Instruments
630 Exterior Lighting
640 Heating and AirConditioning
650 Radio

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Foreword
This BMW 5-Series Service Manual covers the 1989 through 1995 525i models, the 1989
through 1993 535i models, and the 1994 and 1995 530i and 540i models, and is specifically de-
signed to cover only those models built for sale in the United States.
BMW and mostaccessories and parts sellers specializing in BMWsrefer to the 5-Series covered
by this manual as the E34 model. The code "E34" is BMW's internal code for the basic platform
shared byall of thecarscovered by this manual. Except forthe engine and a few othercomponents,
the models covered by this manual share many of same components such as suspension parts,
body panels, and the interior pieces. When ordering parts, especially body parts,knowing the E34
code may be helpful.
BMW also uses an internal code for the various engines used in the E34 models. The engines
used in the 525i models are either M20, M50, or M50TU. The engine used in the 535i is k
now n as
the M30. The engine used in the 530i and 540i is known as the M60. This information is pri
mar ily
used intemally by BMW, but may be helpful if you have access to BMWtechnical information.
For the BMW owner with basic mechanical skills, this manual gives detailed maintenance and
repair information. In addition, the BMW owner who has no intention of working on his or her own
car will find that owning and reading this manual will make it possible to be better informed and to
discuss repairs more intelligently with a professional technician. This manual has been prepared
from the repair information that BMW provides to its factory-trained technicians and has been de-
veloped primarily with the do-it-yourself BMW owner in mind. The aim throughout has been clarity
and understanding with practical functional descriptions, step-by-step procedures, and accurate
specifications.
The BMW owner intending todo maintenanceand repair should have a set of tools including a set
of metric wrenches and sockets, screwdrivers. a torque wrench,and feeler gauges, since these ba-
sic tools will be used to do the majority of Ihe maintenance and repair procedures described in this
manual.This manual includes detailed information on these basic tools and other tips for the begin-
nerin the first section of the manual, entitled Fundamentals for the Do-It-YourselfOwner. For some
of the repairs described in this manual, BMW technicians use special tools. The text will note when
a repair requires these special tools and. where possible, will recommend practical alternatives.
v

vi
We have endeavoured to ensure the highest degreeof accuracy possible.Whenthe vastarray of
data presented in the manual is taken into account, however, no claim to infallibility can be made.
We therefore cannotbe responsible forthe resultof any errors that mayhave crept into the text. The
publisherencourages comments from the readers of this manual in regard to any errors and, also.
suggestions for improvement in the presentation of technical material. These communications
have been and will be carefully considered in the preparation of future printings of this and other
manuals. Please write to Robert Bentley. Inc.•Cambridge. Massachusetts 02138.
BMW offers extensive warranties. especially on components of the fuel delivery and emissions
control systems. Therefore. before deciding to repair a
BMW that may still be covered wholly or in
part by any warranties issued by BMW of NorthAmerica,consult your authorized BMW dealer. You
may find that he can make the repair either free
or at minimum cost.
Regardless of its age and whether or not it is still protected by warranty.your BMW is both an
easy car to service and an easycar to get serviced. So if at any time a repair is needed that you feel
is too difficult to do yourself. a trained
BMW technician is ready to do the job for you. Each autho-
rized BMW dealerservice department has made a significant investment in service and diagnostic
test equipment. specials tools, and BMW original parts. He is also the best source of the most up-
to-date repair and service techniques. which includes factory training and technical literature. Ser-
vicing your BMWthrough an authorized BMWdealerwill Insure that your investment will be protect-
ed while maintaining the highest degree of service standards.
Robert Bentley

Please read these warnings and cautions
before proceeding with maintenance and repair work.
WARNIN G-
•Some repairs may be beyond your capability. If you lack the
skills, tools and equipment, or a suitable workplace for any proce-
dure described in this manual, we suggest you leave such repairs
to an authorized BMW dealer servicedepartment, or other quali-
fied shop.
• Do not re-use any fasteners that are wom or deformed in normal
use. Many fasteners are designed to be used only once and
become unreliable and may fail when used a second time. This
includes, but is not limited to, nuts, bolts, washers, self-locking
nuts or bolts. circlips and cotter pins. Always replace these fasten-
ers with new parts.
•Never work under a lifted car unless it is solidly supported on
stands designed for the purpose. Do not support a car on cinder
blocks, hollow tiles or other props that may crumble under contin-
uous load. Never work under a car that is supported solely by a
jack. Never work under the car while the engine is running.
• If you are going to work under a car on the ground, make sure
that the ground is level. Block the wheels to keep the car from roil-
ing. Disconnect the battery negative Hterminal (Ground strap) to
prevent others from starting the car while you are under it.
•Never run the engine unless the work area is well ventilated.
Carbon monoxide kills.
• Finger rings, bracelets and other jewelry should be removed so
that they cannot cause electrical shorts. get caught in running
machinery, or be crushed by heavy parts.
•
lie long hair behind your head. Do not wear anecktie, a scarf,
loose clothing,or a necklace when you work near machine tools or
running engines. If your hair, clothing, or jewelry were to get
caught in the machinery, severe injury could result.
• Do not attempt to work on your car if you do not feel well. You
increase the danger of injury to yourself and others if you are tired,
upset or have taken medication or any other substance that may
keep you from being fully alert.
• Illuminate your work area adequately but safely. Use a portable
safety light for working inside or under the car. Make sure the bulb
is enclosed by a wire cage. The hot filament of an accidentally bro-
ken bulb can ignite spilled fuel or oil.
• Catch draining fuel, oil, or brake fluid in suitable containers. Do
not use food or beverage containers that might mislead someone
into drinking from them. Store flammable fluids away from fire haz-
ards.Wipe up spills at once, but do not store the oily rags, which
can ignite and burn spontaneously.
• Always observe good workshop practices. Wear goggles when
you operate machine tools or work with battery acid. Gloves or
other protective clothing should be worn wheneverthe job requires
working with harmful substances.
•Greases, lubricants and other automotive chemicals contain
toxic substances,many of which are absorbed directly through the
skin. Read manufacturer's instructions and warnings carefully.
Use hand and eye protection. Avoid direct skin contact.
• Friction materials such as brake or clutch discs rnay contain
asbestos fibers. Do not create dust by grinding,sanding, or by
cleaning with compressed air.Avoid breathing asbestos fibers and
asbestos dust. Breathing asbestos can ca
use serious diseases
such as asbestosis or cancer, and may result in death.
• Disconnect the battery negative (
-) terminal (Ground strap)
whenever you work on the fuel system or the electrical system. Do
not smoke or work near heaters or other fire hazards. Keep an
approved fire extinguisher handy.
•
Balleri es give off exp losive hyd rogen gas dur ing charging.
Keep sparks, lighted matches and open flame away from the top
of the battery. lf hydrogen gas escaping from the cap vents is
ignited, it will ignite gas trapped in the cells and cause the battery
to explode.
• Connect and disconnect battery cables, jumper cables or a bat-
tery charger only with the ignition switched off, to preventsparks.
Do not disconnect the battery while the engine is running.
• Do not quick-charqe the battery (for boost starting) for longer
than one minute. Wait at least one minute before boosting the bat-
tery a second time.
• Do not allow battery charging voltage to exceed 16.5 volts. If the
battery begins producing gas or boiling violently, reduce the charg-
ing rate. Boosting a sulfated battery at a high charging rate can
cause an explosion.
• The air-conditioning system is filled with chemical refrigerant,
which is hazardous. The AlC system should be serviced only by
trained technicians using approved refrigerant recovery/recycling
equipment. trained in related safety precautions, and familiar with
regulations governing the discharging and disposal of automotive
chemical refrigerants.
• Do not expose any part of the AlC system to high temperatures
such as open flame. Excessive heat will increase system pressure
and may cause the system to burst.
•Some aerosol tire inflators are highly flammable. Be extremely
cautious when repairing a tire that may have been inflated using
an aerosol tire inflator. Keep sparks, open flame or other sources
of ignition away from the tire repair area. Inflate and deflate the tire
at least four times before breaking the bead from the rim. Com-
pletely remove the tire from the rim before attempting any repair.
• Some cars covered by this manual are equipped with a supple-
mental restraint system (SRS), that automatically deploys an
airbag in the event of a frontal impact. The airbag is inflated by an
explosive device.Handled improperly or withoutadequate safe-
guards, it can be accidently activated and cause serious injury.
• On cars equipped with anti-lock brakes (ABS),the ABS modular
assembly is capable of "selt-pressurinq" up to 210 bar (3045 psi).
Serious injury
may result if the unit is not properly depressurized
before servicing the system.
continued on next page
vii

Please read these warnings and cautions
before proceeding with maintenance and repair work.
CAUTION-
• If you lack the skills, tools and equipment. or a suitable work-
shop for any procedure described in this manual. we suggest you
leave such repairs to an authorized BMW dealer or other qualified
shop.
• BMW is constantly improving its cars and sometimes these
changes, both in parts and specifications. are made applicable to
earlier models. Therefore, part numbers listed in this manual are
for reference only.Always check with your authorized BMW dealer
parts department for the latest information.
• Before starting a job, make certain that you have all the neces-
sary tools and parts on hand. Read all the instructions thoroughly,
do not attempt shortcuts. Use tools appropriate to the work and
use only replacement parts meeting BMW specifications. Make-
shift tools. parts and procedures will not make good repairs.
• Use pneumatic and electric tools only to loosen threaded parts
and fasteners. Never use these tools to tighten fasteners, espe-
cially on light alloy parts. Always use a torque wrench to tighten
fasteners to the tightening torque specification listed.
• Be mindful of the environment and ecology. Before you drain the
crankcase, find out the proper way to dispose of the oil. Do not
pour oil onto the ground, down a drain, or into a stream. pond or
lake. Consult local ordinances that govem the disposal of wastes.
• On cars equipped with the anti-lock brakes (ABS). the ABS con-
trol unit cannot withstand temperatures from a paint-drying booth
or a heat lamp in excess of 203°F (95°C) and should not be sub-
jected to temperatures in excess of 185°F (85°C) for more than
two hours.
viii
• Before doing any electrical welding on cars equipped with ABS,
disconnect the battery negative
(-) terminal (Ground strap) and
the ABS control unit connector.
• On cars equipped with anti-theft radios, make sure you know
the correct radio activation code before disconnecting the battery
or removing the radio. If the wrong code is entered into the radio
when power is restored, that radio may lock up and be rendered
inoperable. even if the correct code is then entered.
• Connect and disconnect a battery charger only with the battery
charger switched off.
• Do not quick
-Cha rge the battery (for boost starting) for longer
than one minute. Wait at least one minute before boosting the bat-
tery a second time.
• Sealed or "maintenance free" batteries should be slow-charged
only, at an amperage rate that is approximately 10% of the bat-
tery's ampere-hour (Ah) rating.
• Do not allow battery charging voltage to exceed 16.5 volts. If the
ballery begins producing gas or boiling violently,reduce the charg-
ing rate. Boosting a sulfated battery at a high charging rate can
cause an explosion.

FUNDAMENTALS FOR THE DO-iT-YOURSELF OWNER
010 FUNDAMENTALS FOR THE
DO-IT-YOURSELF OWNER
010-1
GENERAL. ".010-1
HOW TO USE THIS MANUAL 010-2
Warnings, Cautions and Notes 010-2
GETTING STARTED 010-2
Safety 010-2
Lifting the Car. 010-3
To raise car safely 010-3
To work safely under car 010-4
ADVICE FOR THE BEGINNER 010-4
Planning Ahead 010-4
Cleanliness 010-4
Non-reusable Fasteners 010-4
Tightening Fasteners 010-4
Gaskets and Seals 010-5
Electrical Testing 010-5
Wire Repairs 010-6
BUYING PARTS 010-6
Genuine BMW Parts 010-6
Non-returnable Parts 010-6
Information You Need To Know 010-7
SERVICE 010-7
GENERAL
Although the BMW is a sophisticated and complex machine,
basic maintenance can be accomplished by an interested own-
er with mechanical skills and the right information. Most of the
preventive maintenance that is required in the lifetime of the av-
erage BMW is well within the capabilities of the do-it-yourselfer.
WARNING-
Do not use this manual unless you are familiar with
basic automotive repair procedures and safe work-
shop
pr actices. This manual illustrates the work-
shop procedures required for most service work: it
is not asubstitute for full and up-to-date information
from the vehicle manufacturer or for
pr oper training
as an automotive technician. Note that it is not pos-
sible for us to anticipate all
of the ways or conditions
under which ve
hi cles may be serviced or to pr ovide
cautions
as to all of the possible hazards that may
result.
TOOLS 010-7
Basic Tool Requirements 010-8
Jack Stands 010-9
Oil Change Equipment 010-10
Torque Wrench 010-10
Feeler Gauges 010-10
Volt-Ohm Meter (VOM) or Multimeter 010-11
BMW Special Tools 010-1 1
EMERGENCIES 010-11
Changing a Tire 010-11
Car Will Not Start 010-12
Jump Starting 010-12
To jump start car. 010-12
Overheating 010-13
Low Oil Pressure 010-13
Brake Fluid Level 010-13
Check Engine Warning Light 010-13
Dim Lights 010-13
Towing 010-14
Spare Parts Kit 010-14
TABLES
a. General Bolt Tightening Torques in Nm
(max. permissible) 010-5
WARNfNG-
Yo ur common sense and good jUdgment are crucial
to safe and successful service work. Read
pr oce-
dures through before starling them. Think about
whether the condition
of your car. y our level of me-
chanical skill. or your level
of re ad ing compretien-
sion might result in or contribute in some way to an
occurrence that might cause you injur
y, damage
your
car. or result in an unsafe repa ir . If you have
doubts for these or otherreasons
abo ut your ability
to perform safe repair work on your car. have the
work done at an authorized
BMW dealer or other
qualified shop.
This section of the manual is intended to help the beginner
get started.To begin with there is a discussion on
How To Use
This Manual. Tips on mechanic's skills and workshop practic-
es that can help the beginnerdo a faster and more thorough job
can be found under
Getting Started. The basic tools needed
to do most of the procedures in this manual are found under
Tools .The section ends with a quick reference guide to Emer-
gencies , including basic troubleshooting and information on
how to gauge the seriousness of a problem.
GENERA L

010-2 FUNDAMENTALS FOR THE DO-IT-YOURSELF
OWNER
How To USETHIS MANUAL
The manual is divided into nine sections:
oGENERAL DATA AND MAINTENANCE
1 ENGINE
2TRANSMISSION
3SUSPENSION,STEERING AND BRAKES
4 BODY
5 BODY EQUIPMENT
6 ELECTRICAL SYSTEM
7EQUIPMENT AND ACCESSORIES
ELECTRICAL WIRING DIAGRAMS
oGENERAL DATA AND MAINTENANCE covers the rec-
ommended maintenance schedules and service procedures
needed to do BMW scheduled maintenance work. Also within
this section is the 010
Fundamentals for the Do-It-yourself
Owner section, which contains basic instructions. tips and
helpful hints for do-it-yourself maintenance and repair.
The next seven sections
(1 through 7) are repair based and
are furtherbroken down into three digit repairgroups. Each ma-
jor section begins with a General repair group. e.g. 100 En-
gine-General. These "00" (double zero) groups are mostly
descriptive in nature, covering topics such as theory of opera-
tion and troubleshooting. The remainder of the repair groups
contain the more involved repair information. The last major
section contains detailed electrical wiring diagram schematics.
A master listing of the 9 major sections and the correspond-
ing individual repair groups can be found on the inside front
cover.
Each repair group begins with a Table of Contents listing the
major subject headings within the group. Page numbers
throughout the manual are organized according to the repair
group system. For example. you can expect to find repair infor-
mation on brakes (Repair Group 340) beginning on page 340
-1 .
Acomprehensive index can be found at the back of the manual.
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 u nd er t hi s heading warns of unsafe pr ac-
tices that are very likely to cause inju
ry, either by di-
rect Ihre
at to the personts} doing the work or by
i nc reased risk of a cci de nt or mechanical failure
w
hil e dri ving.
CAUTfON-
Acaution calls sttention to important pr ecautions
to be observ
ed during the repair work that will help
pr eventaccidentally d am aging the car or its parts.
GETTING STA RTED
NOTE-
Anote contains helpful i nf ormation, tips that wi ll help in
doing a
bett er job and compl el ing it more easily.
Please read every WARNING,CAUTION, and NOTE at the
front of the manual and as they appear in repair procedures.
They are very important. Read them before you begin any
maintenance or repair job.
Some WARNINGs and CAUTIONs are repeated wherever
they apply. Read them all. Do not skip any. These messages
are important, even to the owner who never intends to work on
the car.
GETTING STARTED
Most of the necessary maintenance and minor repair that an
automobile will need can be done with ordinary tools, even by
owners with little or no experience in car repair. Below is some
important information on how to work safely, a discussion of
what tools will be needed and how to use them,and a series of
mechanic's tips on methods and workmanship.
Safety
Although an automobile presents many hazards. common
sense and good equipment can help ensure safety.Many acci-
dents happen because of carelessness.Pay attention and stick
to these few important safety rules.
WARNING-
• Never run the en gi ne in the work area unless it
is well-ve nt ilated. The exhaust should be ve nted
to the outs id e. Carbon Monox id e (CO) in the ex-
haust kills.
• Remove
all neckties, scarfs. loose clothing. or
jewelry when working ne ar run ni ng en gi nes or
power tools. Tu ck in shirts. Tie long hair and se-
cure it
und er ac ap .Severe injury can result from
these things being caught in rotating parts.
• Remove rings. watches, and
br acelets. Aside
from the dangers
of moving parts, metallic jew -
elry conducts electricity and may cause shorts,
s
pa rks. burns. or d am age to the electrical sys-
tem when
acci dentally contacting the batt er yor
otherelectrical termin al s.
• Disconnect the b
all ery neg at ive (-) cable when-
ever working on or near the fuel sy
st em or any-
thing that is el
ec trically pow ered. Acc id en tal
electrical contact may damage the electrical
systemor cause afire.

FUNDAMENTALS FOR THE DO-IT-YOURSELF OWNER
010-3
o
8348 FUN.8
8348.FUN.8
Fig. 1. BMW jacking points (arrows).
• Illuminate the work area adequately and safely.
Use aportable
saf ety light for working inside or
underthe car.Afluorescent type light is best be·
cause it
gi ves off less heat. If using alight wif/) a
normal incandescent bulb. use rough service
bulbs to avoid breakage. The hot filament
of an
accidentally broken bulb can ignite spill
ed fuel or
oil.
• Fuel is highly flammable. When working around
fuel. do not smoke
or work nearheaters or other
fire hazards. Keep an approved lire extinguisher
handy.
WARNING-
• Never work under alifted car unless it is solidly
supported on jack stands that are intended for
that purpose. Do not support acar on cinder
blocks. bricks. or other objects that may shift
or
crumble under continuous load. Never work an-
ti eracar that is supported only by the liftingjack.
• Keep sparks. lighted matches.
and any open
flame away from the top of the batt
er y. Hydro-
gen gas emitted by the batt er y is highly flamma-
ble.Any nearby source
of ignition may cause the
battery to explode.
• Never lay tools or p
ar ts in the engine compart-
ment or on top of the batt
er y. They may fall into
confined s
pac es and be difficult to retrieve. be-
come caught in belts or oth er rotating parts
when the engine is started. or cause electrical
sh
or ts and damage to the electrical system.
• The fuel system is design
ed to retain pressure
even when the ignition is off. When working with
the fuel system. loosen the fuel lines slowly to et-
low the residual pr essure to dissipate gr aduall y.
Take pr ecautions to avoid spraying fuel.
Lifting the Car
For those repairs that require raising the car,the proper jack-
ingpoints should be used to raise the car safely and avoid dam-
age. There are four jacking points from which the car can be
safely raised. The jack supplied with the car by BMW can only
be used at the four side
points-just behind the front wheel or
just in front of the rear wheel. See Fig. 1.
WARNING-
• When raising the car using afloor jack or ahy-
draulic lift. carefully position the jack pad to
pr e-
vent damaging the car body. Asuitable liner
(wood, rubber. etc.) should be
pl aced between
the jack and the car to prevent body damage.
To raise car safely
1. Park the car on a flat. level surface.
2. Place the jack in position.See Fig.2. Make sure the jack
is resting on flat. solid ground. Use a board or other sup-
port to provide a firm surface for the jack. if necessary.
Fig. 2. BMW supplied jack correctly positioned under front jacking
point.
• Watch the jack close ly. Make sur e it stays stable
and does not shift or tilt. As the car is raised. the
car may roll slightly and the jack may shift.
3. Raise the car slowly while constantly checking the po-
sition of the jack and the car.
4. Once the car is raised. block the wheel that is opposite
and farthest from the jack to prevent the car from unex-
pectedly rolling.
G ETT ING STARTED

010-4 FUNDAMENTALS FOR THE DO-IT-YOURSELF
OWNER
WARNING-
• Do not rely on the transmission or the emergen-
cy brake to keep the car from rolling. They are
not asubstitute for positively blocking the oppo-
site wheel.
•Never work underacarthat is supported only by
a jack. Use jack stands that are properly de-
signed to support the car. See Tools.
To work safely under car
1. Disconnect the battery negative (-) cable so that no
one else can start the car.Let others know what you will
be doing.
2. Raise the car slowly as described above.
3. Use at least two jack stands to support the car. A jack
is a temporary
lif1 ing device and should not be used
alone to support the car while you are under it. Use jack
stands designed for the purpose of supporting a car.
For more information on jack stands, see
Tools below.
WARNING-
Do not use wood. concrete blocks, or bricks to sup-
port a ca
r. Wood may split. Blocks or bricks. while
strong, are not design
ed for that kind of load, and
may break or collapse.
4. Place the jack stands on a firm, solid surface. If neces-
sary, use a flat board or similar solid object to provide a
firm footing.
5. Lower the car slowly until its weight is fully supported
by the jack stands. Watch to make sure that the jack
stands do not tip or lean as the car settles on them.
6. Observe all jacking precautions again when raising the
car to remove the jack stands.
ADVICE FOR THE BEGINNER
The tips in the paragraphs that follow are general advice to
help any do-it-yourself BMW owner perform repairs and main-
tenance tasks more easily and more professionally.
Planning Ahead
Most of the repairs and maintenance tasks described in this
manual can be successfully completed by anyone with basic
tools and abilities.Some cannot. To prevent getting intoo deep,
know what the whole job requires before starting. Readthe pro-
cedure thoroughly, from beginning to end, in order to know just
what to expect and what parts will have to be replaced.
ADVICE FOR THE BEGINNER
Cleanliness
Keeping things organized, neat,and clean is essential to do-
ing a good job. When working under the hood, fender covers
will protect the finish from scratches and other damage. Make
sure the car is relatively clean so that dirt under the cover does
not scratch the finish.
Any repair job will be less troublesome if the parts are clean.
For cleaning old parts, many solvents and parts cleaners are
available commercially.
For cleaning parts prior to assembly,commercially available
aerosol cans of carburetor cleaner or brake cleaner are handy
to use, and the cleaner will evaporate completely.
WARNING-
Virtually all solvents used for cleaning part s are
highly flammable, especially in aerosol form. Use
with extreme care. Do not smoke. Do not use these
products nearanysource
of sparks or flame.
Let any solvent or cleaning product dry completely. Low-
pressure, dry compressed air is helpfUl if available. Also, use
only lint-free rags for cleaning and drying.
WARNING-
Av oid getting tools or clothing near the battery. Bat·
tery electrolyte is a corrosive acid. Be car
eful with
brake fluid, as it can damage the car'spaint. Finall
y,
keep rubberparts such as hoses andbelts free from
oil or gasoline.as they will cause the mat
er ial to
soften and fail prematurely.
Non-reusable Fasteners
Many fasteners used on the cars covered by this manual
mustbe replaced with new ones once they are removed.These
include but are not limited to: bolts, nuts (self-locking, nylock,
etc.),cotter pins,studs, brake fittings, roll pins, clips,and wash-
ers. Genuine BMW parts should be the only replacement parts
used for this purpose.
Some bolts are designed to stretch during assembly and are
permanentlyaltered,renderingthem unusable again.Always re-
place fasteners where instructed to do so. See an authorized
BMW dealer for applications and ordering information.
Tightening Fasteners
When tightening the bolts or nuts that attach acomponent,itis
always good practice to tighten the bolts gradually and evenly to
avoid misalignment or over stressing
anyone portion of the
component. For components sealed with gaskets. this method
helps to ensure that the gasket willseal properly and completely.

FUNDAMENTALS FOR THE DO-iT-YOURSELF OWNER
010-5
B OO1 .FNG
Fig. 3. General sequence for alternately tightening mUltiple fasteners.
Where there are several fasteners, tighten them in a se·
quence alternating between opposite sides of the component.
Rg. 3 shows such a sequence for tightening six bolts attaching
atypical component. Repeat the sequence until all the bolls are
evenly tightened to the proper specification.
For some repairs a specific tightening sequence is neces-
sary, or a particularorder of assembly is required. Such special
conditions are noted in the text,and the necessarysequence is
described or illustrated.Where no specific torque is listed, Ta-
ble a can be used as a general guide for tightening fasteners.
Gaskets and Seals
The smoothest metal mating surfaces still have imperfec-
tions that can allow leakage. To prevent leakage at critical
joints. gaskets of soft, form-fitting material are used to fill in the
imperfections.
Inplaceswhere ashaft must pass through a housing, flexible
lip seals are used to keep the lubricating oil or grease from leak-
ing out past the rotating shaft. Seals should never be reused
once they have been removed. When removing a seal,be care-
ful not to scratch or otherwise damagethe metal surfaces. Even
minor damageto sealing surfaces can cause seal damage and
leakage.
To be most effective, gaskets are designed to crush and be-
come thinner as the mating parts are bolted together. Once a
gasket has been used, it is no longer capable of making as
good a seal as when new, and is much more likely to leak. For
this reason. gaskets should not be reused. Always plan to use
new gaskets for any reassembly.Some
gaskets-such as
headgaskets-are directional. Make sure that these are in·
stalled correctly. This same logic applies to any part used for
sealing, including rubber O-rings and copper sealing washers.
8001FNG
1
@
2
WARNING-
Table ais ageneral reference only The values list-
ed in the table are not intended to be usedas a sub-
stitute for torques specifically called out in the text
throughout this manual.
NOTE-
• Metric bolt classes or grades ar e m ar ked on the bolt
head.
The key to seal installation is to getthe seal instraight without
damaging it. Use an object that is the same diameter as the
seal housing to gently and evenly drive it into place. If a proper
size seal driver is not available,a socket of the right size willdo.
When installing a seal, coat the entire seal with oilto help itgo
in more easily. Seals are directional. Make sure that it is in-
stalled with the lip facing the correct way. Normally the lip faces
the inside. Note the installation direction of the old seal before
removing it.
• Do not confuse wrench size with bolt diametersize.
For alisting of the common wrenches used on vsri-
ous bolt diameters, see Basic Tool Requirements. ElectricalTesting
Table a. General BoltTighteningTorques in Nm
(max. permissible)
Agreat many electrical problems can be understood and
solved with only a little fundamental knowledge of how electri-
cal circuits function.
Bolt Class (according to DIN 267)
Bolt
I
diameter 5.6 5.8 6.8 8.8 I10.9 12.9
---.T
M5 2.5 3.5 i4.5 6810
II
M6 4.5 6 !7.5 10 i14 17
I
M8 11 15 I18 24 34 40
M10 23 30 J36 47 I66 79
1 -
M12
39 52 I62 82 115 140
I
M14
62 82 98 130 I180 220
- - I
M16 94 126 150 200 280 340
M18 130 174 210 280 390 470
Electric current only flows in a complete circuit. To operate.
every electrical device in the car requires a complete circuit in-
cluding 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 battery, whether
through the wiring harness or the car body. Except for portions
of the charging system. all electrical current in the car is direct
current (DC) and flows from positive (+) to negative (
-) .
Switches are used to turn components on or off by complet·
ing or interrupting the circuit. A switch is "open"when the circuit
is interrupted,and "closed"when the circuit is completed.Fig. 4
shows a complete circuit schematically. See 600
Electrical
System-General for electrical troubleshooting.
AO ~ CEFORTHEBE GWNER

010-6 FUNDAMENTALS FOR THE DO-iT-YOURSELF
OWNER
BUYING PARTS
Bal1 ery
Direction
of current flow
~
Light bulb - J
(consumer)I .f. I
Car body I--
(ground)
B0 29ELG
Many of the maintenance and repair tasks in this manual call
for the installation of new parts, or the use of new gaskets and
other materials when reinstalling parts. Most often, the parts
that will be needed should be on hand before beginning the job.
Read the introductory text and the complete procedure to de-
termine which parts will be needed.
NOTE-
For some bigger jobs, partial disassembly and inspec-
tion are required to determine acomplete parts list.
Read the procedure carefully and, if necessary. make
ather arrangements to get the necessary parts while
your car is disassembled.
B029ELG
Fig. 4. Schematic representation of simple circuit for light bulb.
Switch is shown closed. making circuit complete.
Wire Repairs
Repairs to awiring harness deserve special care to make the
repair permanent. The wire ends must beclean. Iffrayed or oth-
erwise damaged,cut offthe end. Ifthe wire is too short,splice in
a new piece of wire of the same size and make two connec-
tions.
Use connectors that are designed for the purpose. Crimped-
on or soldered-on connectors are best. Crimp connectors and
special crimping pliers are widely available. If soldering, use a
needlenose pliers to hold the wire near the solder joint and cre-
ate a "heat dam". This keeps the heat and the solder from trav-
eling up the wire. Always use a solder made specifically for
electrical work (rosin core).
NOTE-
Tw isting wires together is only atemporary repair,
since corrosion and vibration will eventually spoil the
connection.
Insulate the finished connection.Electronics stores can sup-
ply heat-shrinkable insulating tubing that can be placed onto
the wire before connecting, slid over the finished joint, and
shrunk 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 tightly
to sealout moisture.
BUYING PARTS
Genuine BMW Parts
Genuine BMW replacement parts from an authorized BMW
dealer are designed and manufactured to the same high stan-
dards as the original parts. They will be the correct material,
manufactured to the same specifications, and guaranteed to fit
and work as intended by the engineers who designed the car.
Some genuine BMWparts have a limited warranty.
Many independent repair shops make a point of using genu-
ine BMWparts. even though they may at times be more expen-
sive. They know the value of doing the job right with the right
parts. Parts from other sources can be as good, particularly if
manufactured by one of BMWs original equipment suppliers,
but it is often difficult to know.
BMW is constantly updating and improving their cars, often
making improvements during a given model year. BMW may
recommend a newer, improved part as a replacement. and
your authorized dealer's parts department will know about it
and provide it. The BMW parts organization isbest equipped to
deal with any BMWparts needs.
Non-returnable Parts
Some parts cannot be returned for credit. even it they are the
wrong parts for the car. The best example is electrical parts.
which are almost universally considered non-returnable be-
cause they are so easily damaged internally.
Buy electrical parts carefully, and be as sure as possible that
a replacement is needed, especially for expensive parts such
as electronic control units. Itmay be wise to let an authorized
BMW dealer or other qualified shop confirm your diagnosis be-
fore replacing an expensive part that cannot be returned.

FUNDAMENTALS FOR THE DO-IT-YOURSELF OWNER
Information You Need To Know
010-7
Model . When ordering parts it is important that you know the
correct model designation for your car. Models covered in this
manual are 525i, 530i, 535i, and 540i, including Touring mod-
els.
Model Year. This is not necessarily the same as date of
manufacture or date of sale. A 1989 model may have been
manufactured in late 1988, and perhaps not sold until early
1990. It is still a 1989 model. Model years covered by this man-
ual are 1989 through 1995.
Date
of Manufacture . This information is helpful when or-
dering replacement parts or determining if any of the warranty
recalls are applicable to your car.The label on the driver's door
below the door latch will specify the month and year that the car
was built.
Vehicle Identification Number (VIN).This is a combination
of letters and numbers that identify the particular car. The VIN
appears on the state registration document, and on the car it-
self. One location, shown in Fig. 5, is in the rear of the engine
compartment, below the passenger side wiper arm.
811039
Fig. 5. Location of vehicle identification number (\lIN) in rear of en-
gine compartment (arrow).
The National Highway Traffic Safety Administration (NHTSA)
requires passenger cars with a high theft rate to have the VIN
marked on specific parts of the car when manufactured. On
BMW cars. these parts are identified by an adhesive label.
Original parts are identified by a label bearing the VIN and
two BMW roundel logos. Replacement parts have a similar la-
bel.bearing one BMW round
ellogo and the letters DOT·R.See
Fig. 6. Parts or assemblies bearing the label are the engine.
transmission, front and rear bumpers, front fenders. rear quar-
ter panels. hood, trunk lid and doors. These labels should not
be removed as they will tear apart.
B328 FUN B
B328.FUN 8
Fig, 6. Labels used to identify parts. Ori9"'31equipment label will,
VIN number and rounde
llog os (top) a no replacement part la-
bel with one roundel logo.
Engine .BMWs covered in this manual are powered by vari-
ous6-and 8-cylinder engines. For informationon engine codes
and engine application,see
100 Engine-General .
Transmission . The transmission type with its identifying
code may be important when buying clutch parts. seals. gas-
kets. and other transmtsslon-related parts. For information on
transmission codes and applications, see 200
Transmis-
sion-General .
SERVICE
BMW dealers are uniquely qualified to provide service for
BMW cars. Their authorized relationship with the large BMW
service organization means that they are constantly receiving
new tools and equipment,together with the latest and most ac-
curate repair information.
The BMW dealer's service technicians are highly trained and
very capable. Unlike most independent repair shops, autho-
rized BMW dealers are intensely committed to supporting the
BMW product. They share the owner's interest in BMW value.
performance. and reliability. On the other hand, there are many
independent shops that specialize in BMW service and are ca-
pable of doing high quality repair work. Checking with other
BMW owners for recommendations on service facilities is a
good way to learn of reputable BMW shops in your area.
TOOLS
Most maintenance can be accomplished with a small selec-
tion of the right tools. Tools range in quality from inexpensive
junk, which may break at first use. to very expensive and well-
made tools for the professional. The best tools for most do-it-
yourself BMWowners lie somewhere in between.
TO OLS

010-8 FUNDAMENTALS FOR THE DO-IT-YOURSELF OWNER
Many reputable tool manulacturers offer good quality. mod-
erately priced tools with a liletime guarantee.A broken tool can
be exchanged
lor a new one. lor the life 01 the tool. These are
your best buy. They cost a little more. but they are good quality
tools that will do what is expected 01them. Sears' Craftsrnarr"
line is one such source
01 good quality. reasonably priced. and
guaranteed tools.
Some 01the repairs covered in this manual require the use
01
special tools. such as a custom puller or specialized electrical
test equipment. These special tools are called out in text and
can be purchased through an authorized BMW dealer. As an
alternative. some special tools mentioned may be purchased
Irom the lollowing tool manufacturers and/ordistributors:
• Assenmacher Specialty Tools
6440 Odell Place. Boulder.
CO B0301
[phone]
•Baum Tools Unltd. Inc.
P.O. Box B7. Longboat Key. FL 3422B
(BO
O) B4B·6657
• Schley Products Inc.
5350 E. Hunter Ave.• Anaheim Hills. CA 92B07
[phone]
• Zelenda Machine and Tool Corp.
66-02 Austin Street. Forest Hills. NY 11375
(71B) B96-2
2BB
Basic Tool Requirements
The basic hand tools described belowcan be used to accom-
plish most
01 the simple maintenance and repair tasks.
Screwdrivers . The common flat-blade type and the Phillips
type will handle almost all screws used on BMWs.Two or three
different sizes
01 each type will be best. since a screwdriver 01
the wrong size willdamage the screw head. See Fig. 7.
A complete set
01 screwdrivers should also include Torx®
type screwdrivers.
Wrenches. Wrenches come in different styles lor different
uses. Fig. 8 shows several. The basic open-end wrench is the
most widely used. but grips on only two sides. It can spread
apart and slip all more easily. The box-end wrench has better
grip.on all six sides of a nut or bolt.
A 12-point box-end can loosen a nut or bolt where there is
less room lor movement.while a 6-point box-end provides bet-
tergrip. For hex fastenerson fluid lines.like brake lines and fuel
lines. a flare-nut wrench offers the advantages
01 a box-end
wrench with a slot that allows it to lit over the line.
The combination wrench is the most universal. It has one
open-end and one box-end. 10mm and 13mm wrenches are
the most common sizes needed. A more complete set 01
wrenches would include 6mm through 19mm sizes.
TOO LS
(i ) =:] === ~ ::::::
(c:::s:] c :::J
«J
=:] ~@
«J
=:]
?+
( c:s:]
?+
BOO SfNO
BO0 5.FNG
Fig. 7. Common flat-blade (top) and Phillips (bottom) screwdrivers.
Onset screwdriver(right)is used for screws with limited access.
BOO2F NG
B002FNG
F ig. 8. Types of wrench heads. From left. open-end. 12-point box-
end. 6-point box-end. flare nut.
Soc ke ts .Sockets perform the same jobas box-end wrench-
es.but offer greaterflexibility. They are used with a ratchet han-
dle lor speed and convenience and can be combined with
extensions and universal joints (swivels) to reach lasteners
more easily. Sockets come with different size connections to
drive handles or extensions. called the drive size. The most
common drive sizes are 1/4 in.. 3/8 in.•and 1/2 in.
Sockets come in 6-point and 12-point styles. For use with a
ratchet. the 6-point offers a better grip on tight nuts and bolts.
6mm to 19mm sockets arethemost needed sizes. Below isalist
of typical bolt diametersand the corresponding wrenchsizes.

FUNDAMENTALS FOR THE DO-IT-YOURSELF OWNER 010-9
Bolt Diameter and Wrench Size
• M5 8mm
·M6 10mm
• M8 12mm or 13mm
• M10 17mm
• M12 19mm
• M14 22mm
Spark Plug Sockel Aspecial socket for spark plugs is the
correct size. is deep enough to accommodate a spark plug's
length, and includes a rubber insert to both protect the spark
plug from damage and grip it for easier removal. On all engines
except M50 engines. use a 13/16 in. socket. On the multi-valve
M50 engine.use a5/Bin. socket. See Fig. 9.
B003FNG
B003FNG
Fig. 9. Spark plug socket.
Aneedlenose plier is used for gripping small and poorly ac-
cessible objects. and is useful for wiring and other electrical
work. A locking plier such as the Vise-Grip®is useful because
of its tight grip.
Snap-ring and circlip pliers with special tipped jaws are used
to remove and installsnap-rings or circlips. A Channel-lock" or
water pump plier has adjustable jaws that can be quickly
changed to match the size of the object being held to givegreat-
er leverage.
An adjustable wrench can be a useful addition to a small tool
kit. See Fig.
11 . It can substitute in a pinch. if two wrenches of
the same size are needed to remove a nut and bolt. Use extra
care with adjustable wrenches.as they tend to loosen,slip.and
damage fasteners.
BOOSf: NG
BOOBF NG
Fig. 11.Adjustable wrench.
Compared to a wrench of the correct size. an adjustable
wrench is always second best. They should only be used when
the correct size wrench is not available.Choose one of average
size range. about 6 to 8 inches in len
g1h .
Pliers.A few of the many types of pliers are shownin Fig. 10.
Most are used for holding irregular objects. bending, or crimp-
ing. Some have special applications.
SOO6F NG
Jack Stands
Strong jack stands are extremely important for any work that
is done under the car. Jacks are designed only for short term
use and are not solid enough to support the car for a long peri-
od. A jack should never be used alone to support the car while
working underneath.
Use only jack stands that are designed for the purpose.
Blocks of wood. concrete. bricks. etc. are not safe or suitable
substitutes.
Jack stands are available in several styles. A typical jack
stand is shown
in Fig.12.The best ones are made of heavy ma-
terial for strength. have a wide base for stability. and are
equipped to positively lock in their raised positions.Get the best
ones available.
B OO6 .FNG
Fig. 10. Pliers. From left. snap-ring. neec tenose .adjustable-joint
(Cha nnel-lock!» . slip-joint. and locking (Vise-Grip ~) .
TO OLS

010-10 FUNDAMENTA
LS FOR THE DO-IT-YOURSELF OWNER
6C2tFNG
B02 ,FNG
Fig. 12. Jack stand for safely supporting car to work underneath.
BOIBFNG
F ig . 14. Torque wrenches. Inexpensive beam-type (top) is adequate
but must be read visually. Ratchet-type (bottom) can be pre-
set to indicate when torque value has been reached.
Oil Change Equipment
Changing engine oil requires a 17mm socket to loosen and
tighten the drain plug, a drain pan (at least 8 qt. capacity), and
an oil filter wrench. These items are shown in Fig.
13 . A wide,
low drain pan will fit more easily underthe car. Use a funnel to
pour the new oil into the engine.
Atorque wrench with a range up to about 150
Nm (185 ft-Ib)
has adequate capacity for most of the repairs covered in this
manual. For recommended torque values of 10 Nm or below,
the English system equivalent is given in inch-pounds (in-Ib).
These small values may be most easily reached using a torque
wrench calibrated in inch-pounds. To convert inch-pounds to
foot-pounds,divide by
12 .
Feeler Gauges
Feeler gauges are thin metal strips of precise thickness.
used to measuresmallclearances.They are normally available
as a set,covering a range of sizes.
:c -o0
- ~
V0
'"
B022 FNG
B022FNG
Fig. 13. Oil change equipment Includes drain plug wrench (17mm),
8 qt. drain pan, oil filter wrench, and funnel.
B020FNG
Torque Wrench
A torque wrench is used to precisely tighten threaded fasten-
ers to a predetermined value. Nearly all of the repair proce-
dures in this manual include BMW-specified torque values in
Newton-meters (Nm) and the equivalent values in foot-pounds
(ft-Ib).
B020FNG
F ig . 15. Feeler gauge set, used for precise measurement iobs. such
as checking valve clearances.
Several types of torque wrenches are widely available. They
all do the same job. but otter di
Ne rent convenience features at
d
iN erent prices.Two typical torque wrenches are shown in Fig.
14. The most convenient ones have a built-in ratchet. and can
be preset to indicate when a specific torque value has been
reached. Follow the wrench manufacturer's directions for use
to achieve the greatest accuracy.
T OOL S

FUNDAMENTALS FOR THE DO-iT-YOURSELF OWNER
010-11
Volt-Ohm Meter (VOM) or Multimeter
Many of the electrical tests in this manual call for the mea-
surement of resistance (ohms) or voltage values. For safe and
accurate tests of ignition. fuel injection, and emission control
systems. the multimeter, shown in Fig. 16. should be digital,
with high (at least 10,000 ohms) input impedance. Some
meters have automotive functions such as dwell and pulse
width that are useful for troubleshooting ignition and fuel injec-
tion problems.
II I
c.fi l]
,-
0.
~ 0
J :. ~ . ....
.
? -
On --
'dO'.
B019FNG
B019FNG
Fig. 16. Multimeter or Digital Vo lt/ Ohmm eter (DVOM).
CAUTlON-
The DM E system. central bod y electronics. and
otner electronic systems may be damaged by the
high current dr
aw of atest light with anormal in-
candescent bulb.As a
gen er al rule. use a hi gh im -
pedance digital muJrimeter or an LED test light for
all ele ctr ical testing.
BMW SpecialTools
Some ofthe more challenging repairs covered inthis manual
call for the use of BMW special tools. This, however, does not
automatically mean that the job is too complicated or out of
reach ofthe novice.
Many of the BMW special tools mentioned in this manual are
simply the best thing to use to do thejob correctly.Inthese cas-
es, the tool is identified with a BMW part number. See your au-
thorized BMW dealer parts department for information on how
to order specialtools.
There are some jobs for which expensive special tools are
essential, and not a cost-effective purchase for one-time repair
by the do-it-yourself owner. This manual includes such repairs
for the benefit of those with the necessary experience and ac-
cess to tools. For the do-it-yourselfer, the need for specialtools
is noted in the text, and whether or not
BMW dealer service is
recommended.
EMERGENCIES
Changing a Tire
Ifa tire goes flat while driving,pull well off the road.Changing
a tire on a busy street or highway is very dangerous. If neces-
sary.drive a short distance on the flat tire to get to a safe place.
It is much better to ruin a tire or rim than to riskbeing hit.
Stop the car on as flat a surface as possible,ina place where
you can be easily seen by other drivers. Avoid stopping just
over the crest of a hill. Turn on the emergency flashers,and set
out flares or emergency markers well behind the car. Passen-
gers should get out of the car and stand well away from the
road. Take the jack. tools, and spare wheel from the trunk.
Chockthewheeldiagonally opposite to the
one being changed.
Loosen the wheel bolts while the car is on the ground, but
leave them a little snug. Place the jack under the lifting point
nearest the wheel being changed (lifting points are shown in
Fig. 1). Use a board to provide a firm footing for the jack if the
ground is soft. Raise the car only far enough so that the wheel is
off the ground,and then remove the wheel nuts and the wheel.
Install the spare wheel. Install the wheel nuts and tighten
them by hand. then lower the car. With all wheels on the
ground, fully tighten the nuts in a crisscross pattern. Torque the
wheel nuts when installing the wheel. Check the inflation pres-
sure of the spare tire.
Tightening Torques
• Wheel bolts to
wheel hub 100 +10 Nm (74 ±7 ft-Ib)
EMER GENC IES

010-12 FUNDAMENTALS FOR THE DO-IT-YOURSELF OWNER
Car Will Not Start
Ifthe engine turns overslowly or not at all, especially on cold
mornings, the battery may not be sufficiently charged. Jump-
starting the battery from anothercar may help.
WARNING -
On cars with manual transmission,push starting (or
tow starting) acar is not recommended by BMW.
NOTE -
Be sure to re
ad thecautions under Jump Starting pr ior
to boosting alow b
all er y. Failure to lollow the cautions
may result in damage to the electronic components in
the car.
If the engine is turning over at normal speed with the starter
motor, the battery and starter are fine. Check to make sure that
there is fuel in the tank. Do not rely on the fuel gauge,it may be
faulty. Instead, remove the gas filler cap and rock the car. If
there is gas in the tank,you should hear a sloshing soundat the
fillerneck.Ifthere is plenty of fuel in the tank,see 100
Engine-
General for in-depth diagnostics and troubleshooting proce-
dures.
Jump Starting
Cars with discharged or dead batteries can be jump-started
using the good battery from another car. When jump-starting
the engine, always heed the following warnings.
WARNING-
• Ballery acid (electrolyte) can cause severe
burns, and will damage the car and clothing. /I
electr ol yte isspilled, wash the surface with large
quantities
01 water. /Iitgets into eyes, /lush them
with water for seve
rsl mi nutes andcall adoctor.
• B
all eries produce explosive and noxious gas·
ses. Keep sparks and flames
away. Do not
smoke near betteries.
• Do not
ju mp-start the engine it you suspect that
the ballery is lrozen.
Tr apped gas may explode.
Allow the ba
ll ery to thaw tirst.
• Do not quick·charge the b
al/ ery (lor boost stert-
ing) lor longer than one minute. and do not ex-
ceed 15 volts at the
ball ery with the boosting
cables ettecnea.Wait at least one minute belore
boosting the bal/ery asecond time.
EMERGENCIES
To jump start car
1. Place the cars close together, but do not allow them to
touch each other.Turn off the engine of the car with the
good battery.
2. Connect one end of the positive (+) cable to the posi-
tive (+) post of the good battery.Remove the cover
from the positive (
8+ )junction post in the engine com-
partment and connect the other end of the positive (+)
cable to the junction post. See Fig. 17.
NOTE-
Thepositive post is marked with aplus (+) sign.
811040
Fig. 17. Positive (8+) junction post in roar of engine compartment.
Connect positive (+)jumper cable to post (a
rr ow).
3. Connect one end of the negative
(-) cable to the nega-
tive
(-) battery post of the good battery.Connect the
opposite end of the negative cable
(-) to the engine
block of the car with the dead battery.
4. Start the car with the good battery and run the engine
at about 2,000 rpm,then start the car with the dead bat-
tery.
5. With the engine at idle, switch on the headlights,blower
motor and rear window defogger to avoid damaging the
cars electrical system. Then carefully disconnect the
jumper cables, starting with the negative cable on the
engine block.Turn all electrical consumers off.
NOTE-
The engine will need to run lor at least an h our to reo
charge the baller
y.