Haynes BMW 520i & 525e Owners Workshop Manual 185010560X, 9781850105602

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BMW 520i & 525e Owners Workshop Manual A K Legg

LAEMIMI

Models covered BMW 520i & 520i Lux; 1990 cc BMW 525e & 525e Lux; 2693 cc Does not cover 525i or revised range introduced June 1988 (1560-9U1)

Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England

Haynes Publications, Inc 861 Lawrence Drive Newbury Park California 91320 USA

ABODE FGHIJ KLMN

Restoring and Preserving our Motoring Heritage Few people can have had the luck to realise their dreams to quite the same extent and in such a remarkable fashion as John Haynes, Founder and Chairman of the Haynes Publishing Group. Since 1965 his unique approach to workshop manual publishing has

51504 0^25.2-6^ 5141453 00b

proved so successful that millions of Haynes Manuals are now sold every year throughout the world, covering literally thousands of different makes and models of cars, vans and motorcycles. A continuing passion for cars and motoring led to the founding in 1985 of a Charitable Trust dedicated to the restoration and preservation of our motoring heritage. To inaugurate the new Museum, John Haynes donated virtually his entire private collection of 52 cars. Now with an unrivalled international collection of over 210 veteran, vintage and classic cars and motorcycles, the Haynes Motor Museum in Somerset is well on the way to becoming one of the most interesting Motor Museums in the world.

Acknowledgements Thanks are due to Champion Spark Plug, who supplied the illustrations showing spark plug conditions, to Holt Lloyd Limited who supplied the illustrations showing bodywork repair and to Duckhams Oils, who provided lubrication data. Thanks are also due to Sykes-Pickavant Limited who provided some of the workshop tools, and to all those people at Sparkford who assisted in the production of this manual.

A 70 seat video cinema, a cafq and an extensive motoring bookshop, together with a specially constructed one kilometre motor circuit, make a visit to the Haynes Motor Museum a truly unforgettable experience. Every vehicle in the museum is preserved in as near as possible mint condition and each car is run every six months on the motor circuit. Enjoy the picnic area set amongst the rolling Somerset hills. Peer through the William Morris workshop windows at cars being restored, and browse through the extensive displays of fascinating motoring memorabilia.

© Haynes Publishing Group 1992

From the 1903 Oldsmobile through such classics as an MG Midget to the mighty 'E' Type Jaguar, Lamborghini, Ferrari Berlinetta Boxer, and

A book in the Haynes Owners Workshop Manual Series

Graham Hill’s Lola Cosworth, there is something for everyone, young and old alike, at this Somerset Museum.

Printed by J. H. Haynes & Co. Ltd., Sparkford, Nr Yeovil, Somerset BA22 7JJ, England All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 85010 560 X British Library Cataloguing in Publication Data Legg, A. K. (Andrew K.) 1942 BMW 520i & 525e owners workshop manual. 1. Cars. Maintenance & repair I. Title 629.28722 ISBN 1 -85010-560-X

We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Haynes Motor Museum Situated raid-way between London and Penzance, the Haynes Motor Museum is located just off the A303 at Sparkford, Somerset (home of the Haynes Manual) and is open to the public 7 days a week all year round, except Christmas Day and Boxing Day.

Contents Page Acknowledgements

2

About this manual

5

Introduction to the BMW 520i and 525e

5

General dimensions, weights and capacities

6

Jacking, towing and wheelchanging

7

Buying spare parts and vehicle identification numbers

8

General repair procedures

9

Tools and working facilities

10

Conversion factors

12

Safety first!

13

Routine maintenance

14

Recommended lubricants and fluids

19

Fault diagnosis

20

Chapter 1 Engine

23

Chapter 2 Cooling system

56

Chapter 3 Fuel and exhaust systems

65

Chapter 4 Ignition system

90

Chapter 5 Clutch

98

Chapter 6 Manual gearbox and automatic transmission

104

Chapter 7 Propeller shaft and driveshafts

148

Chapter 8 Final drive and differential

154

Chapter 9 Braking system

158

Chapter 10 Suspension and steering

180

Chapter 11 Bodywork and fittings

198

Chapter 12 Electrical system

226

Index

291

Spark plug condition and bodywork repair colour pages between pages 32 and 33

BMW 520i

4

V

About this manual Its aim The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work.

Its arrangement The manual is divided into twelve Chapters, each covering a logical sub-division of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc. It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in

sequence with decimal numbers, according to their position in the Chapter - eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the 'left' or 'right' of the vehicle are in the sense of a person in the driver's seat facing forwards. Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into our manuals at the earliest opportunity. We take great pride in the accuracy of information given in this manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Project vehicles The main project vehicle used in the preparation of this manual, and appearing in many of the photographic sequences was a 1987 BMW 525e Lux.

Introduction to the BMW 520i and 525e The BMW 520i was introduced in October 1981 and the 525e in June 1983. Both models are manufactured to fine limits and live up to the BMW reputation of quality workmanship. The 520i is fitted with a 1990 cc six cylinder engine and the 525e with a 2693 cc six cylinder engine. Both engines are of single overhead camshaft, in-line type with a light alloy cylinder head and cast iron cylinder block. The camshaft is driven by a toothed belt. The 520i is

fitted with either a manual gearbox or automatic transmission, whereas the 525e is only fitted with an automatic transmission. Both models are absolutely conventional in design and should present no problems to the home mechanic. The only area where some extra caution is advisable is in the electronic engine management system and fuel control system.

General dimensions, weights and capacities Dimensions Overall length. Overall width. Overall height. Wheelbase. Front track. Rear track: 520i. 525e. Turning circle.

4620 1700 1415 2625 1430

mm mm mm mm mm

(181.9 in) (66.9 in) (55.7 in) (103.3 in) (56.3 in)

1470 mm (57.9 in) 1460 mm (57.5 in) 10.9 m (35 ft 9 in)

Weights Kerb weight: 520i with manual transmission. 520i with automatic transmission. 525e. Maximum gross vehicle weight: 520i with manual transmission. 520i with automatic transmission. 525e. Maximum roof rack load. Minimum towing weight: Braked trailer: 520i with manual transmission. 520i with automatic transmission 525e. Unbraked trailer. Maximum towing hitch downward load.

1260 kg (27781b) 1260 kg (28221b) 1300 kg (28661b) 1770 kg (39021b) 1790 kg (39461b) 1810 kg (39901b) 75 kg (165 lb)

1400 kg (30861b) 1500 kg (3307 lb) 1500 kg (3307 lb) 500 kg (1102 lb) 50 kg (110 lb)

Capacities Engine oil (including filter). Cooling system: 520i models. 525e models. Fuel tank. Manual gearbox: 240. 242. 245. ZF. Automatic transmission: Fluid capacity (fluid change): ZF-3HP-22. ZF-4HP-22. Refill from dry: ZF-3HP-22. ZF-4HP-22. Final drive capacity (drain and refill): 520i: To 1985. 1986 on. 525e. Power steering system.

4.5 litres (7.9 pints) 10.5 litres (9.2 pints) 11.0 litres (9.7 pints) 70 litres (15.4 gal) 1.05 litres (1.8 pints) 1.0 litres (1.7 pints) 1.5 litres (2.6 pints) 1.15 litres (2.0 pints)

2.0 litres (3.5 pints) 3.0 litres (5.3 pints) 5.7 to 6.1 litres (10.0 to 10.7 pints) 6.4 to 7.5 litres (11.3 to 13.2 pints)

1.5 1.7 1.7 1.2

litres (2.6 litres (3.0 litres (3.0 litres (2.1

pints) pints) pints) pints)

Jacking, towing and wheel changing Jacking

Wheel changing

The jack supplied with the car should only be used for wheel changing, as described later. When raising the vehicle for repair or maintenance, preferably use a trolley or hydraulic jack, with a wooden block as an insulator, to prevent damage to the underbody. Place the jack under the jacking points, which are located behind the front wheels and in front of the rear wheels. Position the axle stands under the jacking points or alternatively beneath the main underbody channels.

To change a roadwheel, first park on a firm level surface if possible. Chock the wheel opposite the one being removed. Apply the hand¬ brake, and engage first or reverse gear on manual gearbox models, or 'P' on automatic transmission models. Lift the floor mat in the luggage compartment, then unscrew the wing nut and remove the spare wheel. Remove the jack from the left-hand side of the luggage compartment. Where fitted, unlock and remove the wheel bolt lock. Remove the trim from the roadwheel and use the brace to slacken the wheel bolts. Pull out the small cover and engage the jack with the jacking point nearest the roadwheel. Make sure that the jack is located squarely on the ground. Raise the jack until the roadwheel is just clear of the ground. Unscrew and remove the wheel bolts and take off the roadwheel. Where necessary remove the hub cap from the spare wheel by releasing the spring. Fit the centering pin from the toolkit which is located on the underside of the boot lid (photo), into one of the tapped holes in the wheel hub. Locate the spare wheel on the centering pin and screw in three of the wheel bolts. Remove the centering pin and screw in the last wheel bolt. Lightly tighten the bolts with the brace. Lower the car to the ground and remove the jack, then tighten the wheel bolts in diagonal sequence. Tighten the bolts as hard as possible using the brace from the toolkit, but have their tightness checked as soon as possible with a torque wrench. When fitting the spare wheel for the first time, it must be checked for tightness after 1000 km (600 miles). Refit the wheel trim, making sure that the valve hole is located over the valve. Tap the trim into position with the palm of the hand.

Towing Towing eyes are provided at the front and rear of the car - the front eye is behind a small hinged panel (photos). When being towed, turn the ignition key to position 1 so that the brake lights, direction indicators, horn and wipers are operational. The hazard lights should also be switched on. Note that with the engine stopped, more effort will be required to stop the car, as the brake servo will be inoperative. In addition the power steering pump will not be operating so more effort will be required to turn the steering wheel. The gear lever should be in neutral on manual gearbox models, or position 'N' on automatic transmission models. Automatic transmission models should not be towed further than 30 miles (50 km) or faster than 30 mph (50 km/h). To tow the car for greater distances, add 1 litre (1.8 pints) of automatic transmission fluid to the transmission, but remem¬ ber to drain the excess fluid before driving the car on the road again. If these conditions cannot be met, or if transmission damage has oc¬ curred, remove the propeller shaft.

Front towing eye

Rear towing eye

Toolkit located on the underside of the boot lid

Buying spare parts and vehicle identification numbers Buying spare parts Spare parts are available from many sources, for example: BMW garages, other garages and accessory shops, and motor factors. Our advice regarding spare part sources is as follows. Officially appointed BMW garages - This is the best source for parts which are peculiar to your vehicle and are not generally available (eg complete cylinder heads, internal gearbox components, badges, interior trim etc). It is also the only place at which you should buy parts if the vehicle is still under warranty. To be sure of obtaining the correct parts, it will be necessary to give the storeman your car's vehicle identification number, and if possible, take the old parts along for positive identifica¬ tion. Many parts are available under a factory exchange scheme - any parts returned should always be clean. It obviously makes good sense to go straight to the specialists on your car for this type of part, as they are best equipped to supply you. Other garages and accessory shops - These are often very good places to buy materials and components needed for the maintenance of your car (eg oil filters, spark plugs, bulbs, drivebelts, oils, and greases, touch-up paint, filler paste, etc). They also sell general accessories, usually have convenient opening hours, charge lower prices and can often be found not far from home. Motor factors - Good factors will stock all of the more important

Vehicle Identification number (VIN)

components which wear out relatively quickly (eg exhaust systems, brake pads, seals and hydraulic parts, clutch components, bearing shells, pistons, valves etc). Motor factors will often provide new or reconditioned components on a part exchange basis - this can save a considerable amount of money.

Vehicle identification numbers Modifications are a continuing and unpublicised process in vehicle manufacture, quite apart from major model changes. Spare parts man¬ uals and lists are compiled upon a numerical basis, the individual vehicle identification numbers being essential to correct identification of the component required. When ordering spare parts, always give as much information as possible. Quote the car model, year of manufacture, body and engine numbers as appropriate. The Vehicle Identification Number is located on the right-hand front wheel arch next to the front suspension strut upper mounting (photo). The body number is located on the seam between the left-hand front wing and inner panel (photo). The engine number is stamped on a machined face on the left-hand side of the cylinder block near the base of the oil level dipstick tube (photo).

Body number location

Engine number

General repair procedures Whenever servicing, repair or overhaul work is carried out on the car or its components, it is necessary to observe the following procedures and instructions. This will assist in carrying out the operation efficiently and to a professional standard of workmanship.

Joint mating faces and gaskets Where a gasket is used between the mating faces of two compo¬ nents, ensure that it is renewed on reassembly, and fit it dry unless otherwise stated in the repair procedure. Make sure that the mating faces are clean and dry with all traces of old gasket removed. When cleaning a joint face, use a tool which is not likely to score or damage the face, and remove any burrs or nicks with an oilstone or fine file. Make sure that tapped holes are cleaned with a pipe cleaner, and keep them free of jointing compound if this is being used unless specifically instructed otherwise. Ensure that all orifices, channels or pipes are clear and blow through them, preferably using compressed air.

0/7 seals Whenever an oil seal is removed from its working location, either individually or as part of an assembly, it should be renewed. The very fine sealing lip of the seal is easily damaged and will not seal if the surface it contacts is not completely clean and free from scratches, nicks or grooves. If the original sealing surface of the compo¬ nent cannot be restored, the component should be renewed. Protect the lips of the seal from any surface which may damage them in the course of fitting. Use tape or a conical sleeve where possible. Lubricate the seal lips with oil before fitting and, on dual lipped seals, fill the space between the lips with grease. Unless otherwise stated, oil seals must be fitted with their sealing lips toward the lubricant to be sealed. Use a tubular drift or block of wood of the appropriate size to install the seal and, if the seal housing is shouldered, drive the seal down to the shoulder. If the seal housing is unshouldered, the seal should be fitted with its face flush with the housing top face.

Screw threads and fastenings Always ensure that a blind tapped hole is completely free from oil,

grease, water or other fluid before installing the bolt or stud. Failure to do this could cause the housing to crack due to the hydraulic action of the bolt or stud as it is screwed in. When tightening a castellated nut to accept a split pin, tighten the nut to the specified torque, where applicable, and then tighten further to the next split pin hole. Never slacken the nut to align a split pin hole unless stated in the repair procedure. When checking or retightening a nut or bolt to a specified torque setting, slacken the nut or bolt by a quarter of a turn, and then retighten to the specified setting.

Locknuts, iocktabs and washers Any fastening which will rotate against a component or housing in the course of tightening should always have a washer between it and the relevant component or housing. Spring or split washers should always be renewed when they are used to lock a critical component such as a big-end bearing retaining nut or bolt. Locktabs which are folded over to retain a nut or bolt should always be renewed. Self-locking nuts can be reused in non-critical areas, providing resistance can be felt when the locking portion passes over the bolt or stud thread. Split pins must always be replaced with new ones of the correct size for the hole.

Special tools Some repair procedures in this manual entail the use of special tools such as a press, two or three-legged pullers, spring compressors etc. Wherever possible, suitable readily available alternatives to the manufacturer's special tools are described, and are shown in use. In some instances, where no alternative is possible, it has been necessary to resort to the use of a manufacturer's tool and this has been done for reasons of safety as well as the efficient completion of the repair operation. Unless you are highly skilled and have a thorough under¬ standing of the procedure described, never attempt to bypass the use of any special tool when the procedure described specifies its use. Not only is there a very great risk of personal injury, but expensive damage could be caused to the components involved.

Tools and working facilities Introduction A selection of good tools is a fundamental requirement for anyone contemplating the maintenance and repair of a motor vehicle. For the owner who does not possess any, their purchase will prove a consider¬ able expense, offsetting some of the savings made by doing-it-yourself. However, provided that the tools purchased meet the relevant national safety standards and are of good quality, they will last for many years and prove an extremely worthwhile investment. To help the average owner to decide which tools are needed to carry out the various tasks detailed in this manual, we have compiled three lists of tools under the following headings: Maintenance and minor repair, Repair and overhaul, and Special. The newcomer to practical mechanics should start off with the Maintenance and minor repair tool kit and confine himself to the simpler jobs around the vehicle. Then, as his confidence and experience grow, he can undertake more difficult tasks, buying extra tools as, and when, they are needed. In this way, a Maintenance and minor repair tool kit can be built-up into a Repair and overhaul tool kit over a considerable period of time without any major cash outlays. The experienced do-it-yourselfer will have a tool kit good enough for most repair and overhaul procedures and will add tools from the Special category when he feels the expense is justified by the amount of use to which these tools will be put. It is obviously not possible to cover the subject of tools fully here. For those who wish to learn more about tools and their use there is a book entitled How to Choose and Use Car Tools available from the publishers of this manual.

Maintenance and minor repair toot kit The tools given in this list should be considered as a minimum requirement if routine maintenance, servicing and minor repair oper¬ ations are to be undertaken. We recommend the purchase of combi¬ nation spanners (ring one end, open-ended the other); although more expensive than open-ended ones, they do give the advantages of both types of spanner. Combination spanners - 10, 11, 12, 13, 14 & 17 mm Combination spanners - J-g, h A, I, H- f & ftin AF Adjustable spanner - 9 inch Gearbox/rear axle drain plug key Spark plug spanner (with rubber insert) Sparkplug gap adjustment tool Set of feeler gauges Brake bleed nipple spanner Screwdriver - 4 in long x i in dia (flat blade) Screwdriver - 4 in long x \ in dia (cross blade) Combination pliers - 6 inch Hacksaw (junior) Tyre pump Tyre pressure gauge

OH can Oil filter removal tool Fine emery doth (1 sheet) Wire brush (small) Funnel (medium size)

Repair and overhaul tool kit These tools are virtually essential for anyone undertaking any major repairs to a motor vehicle, and are additional to those given in the Maintenance and minor repair list. Included in this list is a comprehen¬ sive set of sockets. Although these are expensive they will be found invaluable as they are so versatile - particularly if various drives are included in the set. We recommend the \ in square-drive type, as this can be used with most proprietary torque wrenches. If you cannot afford a socket set, even bought piecemeal, then inexpensive tubular box spanners are a useful alternative. The tools in this list will occasionally need to be supplemented by tools from the Special list. Sockets (or box spanners) to cover range in previous list Reversible ratchet drive (for use with sockets) Extension piece, 10 inch (for use with sockets) Universal joint (for use with sockets) Torque wrench (for use with sockets) Self-locking grips Ball pein hammer Soft-faced hammer, plastic or rubber Screwdriver - 6 in long x ^in dia (flat blade) Screwdriver - 2 in long x -^in square (flat blade) Screwdriver - 1\ in long x i in dia (cross blade) Screwdriver - 3 in long x ^ in dia (electricians) Pliers - electricians side cutters Pliers - needle-nosed Pliers - circlip (internal and external) Cold chisel - J? inch Scriber Scraper Centre punch Pin punch Hacksaw Brake hose clamp Brake/clutch bleeding kit Selection of twist drills Steel rule/straight-edge Allen keys (inc. splinedfTorx type if necessary) Selection of files Wire brush (large) Axle-stands Jack (strong trolley or hydraulic type) Light with extension lead

Tools and working facilities Special tools The tools in this list are those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturers' instructions. Unless relatively difficult mechanical jobs are undertaken frequently, it will not be economic to buy many of these tools. Where this is the case, you could consider clubbing together with friends (or joining a motorists' club) to make a joint purchase, or borrowing the tools against a deposit from a local garage or tool hire specialist. The following list contains only those tools and instruments freely available to the public, and not those special tools produced by the vehicle manufacturer specifically for its dealer network. You will find occasional references to these manufacturers' special tools in the text of this manual. Generally, an alternative method of doing the job without the vehicle manufacturers' special tool is given. However, sometimes, there is no alternative to using them. Where this is the case and the relevant tool cannot be bought or borrowed, you will have to entrust the work to a franchised garage. Valve spring compressor Coil spring compressors Piston ring compressor Baiijoint separator Universal hub/bearing puller impact screwdriver Micrometer and/or vernier gauge Dial gauge Stroboscopic timing light Dwell angle meter/tachometer Universal electrical multi-meter Cylinder compression gauge Lifting tackle Trolley jack

Buying tools For practically all tools, a tool factor is the best source since he will have a very comprehensive range compared with the average garage or accessory shop. Having said that, accessory shops often offer excellent quality tools at discount prices, so it pays to shop around. There are plenty of good tools around at reasonable prices, but always aim to purchase items which meet the relevant national safety standards. If in doubt, ask the proprietor or manager of the shop for advice before making a purchase.

Care and maintenance of tools Having purchased a reasonable tool kit, it is necessary to keep the tools in a clean serviceable condition. After use, always wipe off any dirt, grease and metal particles using a clean, dry cloth, before putting the tools away. Never leave them lying around after they have been used. A simple tool rack on the garage or workshop wall, for items such as screwdrivers and pliers is a good idea. Store all normal wrenches and sockets in a metal box. Any measuring instruments, gauges, meters, etc, must be carefully stored where they cannot be damaged or become rusty. Take a little care when tools are used. Hammer heads inevitably become marked and screwdrivers lose the keen edge on their blades from time to time. A little timely attention with emery cloth or a file will soon restore items like this to a good serviceable finish.

Working facilities Not to be forgotten when discussing tools, is the workshop itself. If anything more than routine maintenance is to be carried out, some form of suitable working area becomes essential. It is appreciated that many an owner mechanic is forced by circum¬ stances to remove an engine or similar item, without the benefit of a garage or workshop. Having done this, any repairs should always be done under the cover of a roof. Wherever possible, any dismantling should be done on a clean, flat workbench or table at a suitable working height. Any workbench needs a vice: one with a jaw opening of 4 in (100 mm) is suitable for most jobs. As mentioned previously, some clean dry storage space is also required for tools, as well as for lubricants, cleaning fluids, touch-up paints and so on, which become necessary.

11

Another item which may be required, and which has a much more general usage, is an electric drill with a chuck capacity of at least A in (8 mm). This, together with a good range of twist drills, is virtually essential for fitting accessories such as mirrors and reversing lights. Last, but not least, always keep a supply of old newspapers and clean, lint-free rags available, and try to keep any working area as clean as possible.

Spanner jaw gap comparison table Jaw gap (in) 0.250 0.276 0.313 0.315 0.344 0.354 0.375 0.394 0.433 0.438 0.445 0.472 0.500 0.512 0.525 0.551 0.563 0.591 0.600 0.625 0.630 0.669 0.686 0.709 0.710 0.748 0.750 0.813 0.820 0.866 0.875 0.920 0.938 0.945 1.000 1.010 1.024 1.063 1.100 1.125 1.181 1.200 1.250 1.260 1.300 1.313 1.390 1.417 1.438 1.480 1.500 1.575 1.614 1.625 1.670 1.688 1.811 1.813 1.860 1.875 1.969 2.000 2.050 2.165 2.362

Spanner size i in AF 7 mm Ain AF 8 mm A in AF; f in Whitworth 9 mm | in AF 10 mm 11 mm Ain AF Ain Whitworth; J in BSF 12 mm i in AF 13 mm \ in Whitworth; Ain BSF 14 mm Ain AF 15 mm Ain Whitworth; f in BSF f in AF 16 mm 17 mm A in AF 18 mm | in Whitworth; Ain BSF 19 mm | in AF H in AF Ain Whitworth; f in BSF 22 mm J in AF { in Whitworth; Ain BSF A in AF 24 mm 1 in AF Ain Whitworth; f in BSF 26 mm 1 Ain AF; 27 mm | in Whitworth; A in BSF A in AF 30 mm A in Whitworth; f in BSF Ain AF 32 mm | in Whitworth; f in BSF 1 Ain AF A in Whitworth; A in BSF 36 mm 1 Ain AF f in Whitworth; 1 in BSF A in AF 40 mm; A in Whitworth 41 mm 1| in AF 1 in Whitworth; A in BSF 1A in AF 46 mm 1Ain AF A in Whitworth; A in BSF A in AF 50 mm 2 in AF A in Whitworth; If in BSF 55 mm 60 mm

Conversion factors Length (distance) = Inches (in) = Feet (ft) = Miles

= Millimetres (mm) = Metres (m) = Kilometres (km)

X 0.0394 X 3.281 0.621 X

= = = = = = = =

X X X X X X X X

0.061 1.76 0.88 0.833 1.057 0.22 0.833 0.264

= = = = = = = =

= Grams (g) = Kilograms (kg)

X X

0.035 2.205

= Ounces (oz) = Pounds (lb)

0.278 4.448 0.1

= Newtons (N) = Newtons (N) = Kilograms-force (kgf; kg)

X X X

3.6 0.225 9.81

= Ounces-force (ozf; oz) = Pounds-force (Ibf; lb) = Newtons (N)

X

0.070

X

14.223

inch

X

0.068

— Kilograms-force per square centimetre (kgf/cm2; kg/cm2) — Atmospheres (atm)

X

14.696

inch

X

0.069

—

X

14.5

inch

X

6.895

= Kilopascals (kPa)

X

0.145

X

0.01

= Kilograms-force per square

X

98.1

X X X

25.4 0.305 1.609

X X X X X X X X

16.387 0.568 1.137 1.201 0.946 4.546 1.201 3.785

X X

28.35 0.454

X X X

inch

Inches (in) Feet (ft) Miles

Volume (capacity) Cubic inches (cu in; in3) Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (Imp qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal)

Cubic centimetres (cc; cm3) Litres (1) Litres (1) US quarts (US qt) Litres (1) Litres (1) US gallons (US gal) Litres (1)

Cubic inches (cu in; in3) Imperial pints (Imp pt) Imperial quarts (Imp qt) Imperial quarts (lmP Qt) US quarts (US qt) Imperial gallons (Imp gal) Imperial gallons (Imp gal) US gallons (US gal)

Mass (weight) Ounces (oz) Pounds (lb)

Force Ounces-force (ozf; oz) Pounds-force (Ibf; lb) Newtons (N)

Pressure Pounds-force per square (psi; lbf/in2; lb/in2) Pounds-force per square (psi; lbf/in2; lb/in2) Pounds-force per square (psi; lbf/in2; lb/in2) Pounds-force per square (psi; lbf/in2; lb/in2) Kilopascals (kPa) Millibar (mbar) Millibar (mbar)

X 100 X 0.0145

=

Millibar (mbar) Millibar (mbar) Millimetres of mercury (mmHg) Inches of water (inH20)

X X X X

0.75 0.401 0.535 0.036

= = =

X

1.152

Bars

centimetre (kgf/cm2; kg/cm2) Pascals (Pa) Pounds-force per square inch (psi; lbf/in2; lb/in2) Millimetres of mercury (mmHg) Inches of water (inH20) Inches of water (inH20) Pounds-force per square inch (psi; lbf/in2; lb/in2)

= Pounds-force per square (psi; lbf/in2; lb/in2) = Pounds-force per square S(psi; lbf/in2; lb/in2) = Pounds-force per square (psi; lbf/in2;. lb/in2) = Pounds-force per square (psi; lbf/in2; lb/in2) = Kilopascals (kPa)

X 0.01 X 68.947

= Millibar (mbar) = Millibar (mbar)

X X X X

1.333 2.491 1.868 27.68

= = = =

= Kilograms-force centimetre

X

0.868

X

8.85

=

inch inch inch inch

Millibar (mbar) Millibar (mbar) Millimetres of mercury (mmHg) Inches of water (inH20)

Torque (moment of force) Pounds-force (Ibf in; lb in) Pounds-force (Ibf in; lb in) Pounds-force (Ibf in; lb in) Pounds-force

inches inches

X

0.113

(kgf cm; kg cm) = Newton metres (Nm)

inches

X

0.083

= Pounds-force feet (Ibf ft; lb ft)

X

12

feet (Ibf ft; lb ft)

X

0.138

X

7.233

Pounds-force feet (Ibf ft; lb ft) Newton metres (Nm)

X X

1.356 0.102

— Kilograms-force metres (kgf m; kg m) = Newton metres (Nm) Kilograms-force metres = (kgf m; kg m)

= Pounds-force (Ibf in; lb in) = u s; tg > ^ to O^toK'QoCjoaOO^^ (*) Mfrirstor-Ntsooscs^cMCoMf OoOOCOOOOoOoMJ-MJ-MJ-'q-M}.

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03 03

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No

Key to Fig. 12.16 No

Description

No

Description

1 2 3 4 5 6

Plug - rear section to centre section Connection for special equipment plug Connection for central lock control unit Central lock electronic control unit (A pillar end plate) Plug - driver's door wire to rear section Plug - central lock connecting wire to driver's door wire (13-pin) Plug - central lock connecting wire to passenger's door wire Plug - driver's door central lock wire to switch Central lock switch/unblocking arrest (driver's door, on lock) Connection for central lock motor to driver's door (6-pin) Central lock motor - driver's door Plug - passenger's door wire to microswitch Microswitch (passenger's door, on lock) Central lock motor - passenger's door Central lock motor - passenger's door Connection for central lock motor to boot lid (6-pin) Central lock motor - boot lid Connection for central lock motor to fuel tank flap (6-pin) Central lock motor -fuel tank flap Connection for central lock motor to left rear door (6-pin) Central lock motor - left rear door Connection for central lock motor to right door (6-pin) Plug - central lock connecting wire to right rear door (7-pin) Plug - central lock connecting wire to left rear door (7-pin) Central lock motor - right rear door Rear window heater switch Burglar alarm electronic control unit (left of steering column) Connection for burglar alarm electronic control unit 1 (26-pin) Connection for relay box (4-pin) Connection for burglar alarm electronic control unit II (4-pin) Plug 150 (in main wire harness) Light diode for burglar alarm Plug for boot light Boot light Door contact switch front left Door contact switch front right Door contact switch rear left Door contact switch rear right Boot lid contact Bonnet contact Rear window heater Plug - centre section to wire for on-board computer/burglar alarm Horn Plug for light diode

45 46 47 48 49 50 51 52

Diode Plug - burglar alarm wire to central lock connecting wire Gong (left of steering column) Connection for gong Plug - centre section to LE-Jetronic. wire harness Ignition switch Remote control switch for on-board computer Plug - on-board computer to outside temperature sensor wire Plug - outside temperature sensor wire to outside tempera¬ ture sensor Outside temperature sensor (lower front panel) Plug - extra heater wire to automatic aerial Parked car heating electronic control unit (on parked car heater underneath right seat) Connection for electronic control unit Relay for parked car heater (on heater) Plug - on-board computer wire to extra heater wire Plug - centre section to instrument cluster Connection for instrument cluster On-board computer electronic control unit (right of instru¬ ment cluster) Connection for on-board computer Connection for instrument cluster II Instrument cluster Plug - rear section to instrument cluster Plug - digital clock wire to instrument cluster Plug - extra wire to heater wire Plug - heater wire to fuel pump wire Connection for heater Ballast resistor in heater Thermoswitch (parked car heater) Heater motor Overheating switch (parked car heater) Heater plug for parked car heater Heater Fuel metering pump Plug - on-board computer to remote control Plug - speed dependent loudness control Plug - wire for cruise control Fuel level transmitter Speed transmitter Plug - digital clock wire to digital clock (4-pin) Plug - digital clock wire to digital clock (2-pin) Digital clock

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85

%

264

Fig. 12.16 Wiring diagram for central locking, burglar alarm, on-board computer, additional heater and digital clock

V.

1986 on

/

265 yz y,|

8 hhAj

HoTI |raT1

Rig

54

Fig. 12.16 Wiring diagram for central locking, burglar alarm, c n-board computer, additional heater and digital clock - 1986 on (continued)

266

Fig. 12.17 Wiring diagram for ABS braking system - February 1984 on

Description

No

Description

1

Sensor front right Sensor front left Sensor rear right Sensor rear left Plug - right front sensor to electronic control unit Plug - left front sensor to electronic control unit Plug - right rear sensor to electronic control unit

8 9 10 11 12 13 14

Plug - left rear sensor to electronic control unit Plug - ABS wire harness to cruise control Plug - rear section to centre section Plug - ABS wire harness to special equipment plug (54) Plug - ABS wire harness to special equipment plug (15u, 61) ABS electronic control unit (glove box) ABS lamp

CN 00

No

LO CD

267

1SE

CE

O A

T

A KJ

tr m

Fig. 12.18 Wiring diagram for electric sunroof

H. 22 031

V

No

Description

1 2 3 4 5 6

Plug - sunroof wire to special equipment plug Switch for sunroof Motor for sunroof Microswitch Plug - sunroof wire to microswitch Stepping relay (cowl panel top)

268

a:

o

31

58

15

n u

85

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31b

85

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