Engine Mechanical:
Detailed procedures for engine assembly, disassembly, repair, and overhaul of M20B25 engine.
Engine Management System:
Diagnosis and repair of Bosch Motronic electronic fuel injection and ignition systems.
Fuel System:
Inspection, maintenance, and repair of fuel pump, injectors, fuel lines, and pressure regulator.
Cooling System:
Service procedures for radiator, water pump, thermostat, hoses, and coolant.
Exhaust System:
Inspection and replacement of exhaust manifolds, catalytic converter, mufflers, and pipes.
Transmission Manual:
Repair and overhaul of Getrag 260 5-speed manual transmission, clutch assembly, and shift linkage.
Transmission Automatic:
Diagnosis and repair of ZF 4HP22 4-speed automatic transmission, including valve body and torque converter.
Drivetrain Rear Axle:
Service and repair of differential, driveshaft, and half-shafts.
Suspension Front:
Repair and replacement of MacPherson struts, control arms, ball joints, and sway bar.
Suspension Rear:
Service of trailing arms, shock absorbers, springs, and rear sway bar.
Steering System:
Repair of steering rack, power steering pump, and steering column.
Brake System Front:
Service of vented disc brakes, calipers, pads, and rotors.
Brake System Rear:
Service of solid disc brakes, calipers, pads, and rotors.
Antilock Braking System ABS:
Diagnosis and repair of ABS control module, wheel speed sensors, and hydraulic unit.
Electrical System Charging:
Service of alternator, battery, and voltage regulator.
Electrical System Starting:
Troubleshooting and repair of starter motor, ignition switch, and related circuits.
Lighting System:
Repair and replacement of headlights, taillights, interior lights, and associated wiring.
Instrument Panel:
Diagnosis of gauges, warning lights, and onboard computer systems.
Body Electrical:
Service of power windows, central locking, mirrors, and door modules.
Body Panels:
Repair and replacement procedures for body panels, doors, hood, trunk lid, and bumpers.
Interior Trim:
Removal and installation of dashboard, door panels, seats, and headliner.
HVAC System:
Service of heating, ventilation, and air conditioning systems, including refrigerant.
Routine Maintenance:
Oil changes, filter replacements (oil, air, fuel), spark plug service, coolant flushes, brake fluid changes.
Troubleshooting Diagnostics:
Step-by-step diagnostic charts and procedures for identifying and resolving common and complex issues.
Engine Rebuild:
Detailed instructions for complete engine disassembly, inspection, honing, piston and ring replacement, bearing service, cylinder head refurbishment, and reassembly.
Transmission Repair:
Overhaul procedures for both manual and automatic transmissions, including torque converter replacement, clutch pack replacement (automatic), and gearset service.
Brake System Overhaul:
Caliber rebuild, rotor replacement, brake pad replacement, and bleeding procedures.
Suspension Component Replacement:
Ball joint replacement, control arm bushings, strut and shock absorber replacement, and wheel bearing service.
Electrical Component Testing:
Testing of sensors, actuators, relays, fuses, and wiring harnesses using multimeters and oscilloscopes.
Bodywork Repair:
Procedures for dent removal, panel replacement, welding, and paint preparation.
Depth Level:
Expert-level. Covers everything from basic fluid changes to complete engine and transmission overhauls, including diagnostic trouble codes (DTCs) and circuit diagrams.
Diagrams Illustrations:
Includes detailed exploded views, wiring diagrams, and step-by-step illustrations for complex procedures.
Oil Change Interval:
Every 7,500 - 10,000 miles or 12 months, whichever comes first (check specific conditions).
Spark Plug Replacement:
Typically around 30,000 miles, depending on plug type.
Coolant Flush:
Every 2-3 years or 30,000 miles.
Transmission Fluid Manual:
Inspect fluid level regularly; change if contaminated or at higher mileage intervals (e.g., 60,000-100,000 miles, consult manual).
Transmission Fluid Automatic:
Fluid and filter change recommended every 30,000-50,000 miles for longevity.
Engine Oil Type:
API SG or SH rated, SAE 5W-30 or 5W-40 (check owner's manual for specific viscosity and temperature range).
Coolant Type:
BMW Blue Coolant or equivalent ethylene glycol-based antifreeze/coolant mixture (50/50).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Dexron II/III ATF or specific BMW power steering fluid.
Common Problems:
Coolant leaks (hose, water pump, radiator), fuel distributor issues (M20), OVP relay failures, front control arm bushings, blower motor resistors, dashboard cracks, EWS immobilizer issues (later models, not typically on early E34s).
Electrical Gremlins:
Widespread electrical issues can manifest due to aging wiring and components; requires systematic diagnosis.
