Engine:
M20 6-cylinder (2.7L eta and 2.5L variations)
Fuel System:
Bosch L-Jetronic and Motronic fuel injection, fuel pump, injectors, lines
Ignition System:
Electronic ignition, coil, distributor, spark plugs
Transmission Manual:
Getrag 260 5-speed, clutch assembly, shifter linkage
Transmission Automatic:
ZF 4HP22 4-speed automatic, torque converter, valve body, cooler
Drivetrain:
Rear-wheel drive, driveshaft, differential, half-shafts
Suspension Front:
MacPherson struts, control arms, sway bar, bushings
Suspension Rear:
Semi-trailing arm independent suspension, shock absorbers, springs, bushings
Steering:
Recirculating ball steering system, power steering pump, rack and pinion
Brakes Front:
Ventilated discs, calipers, brake pads, rotors
Brakes Rear:
Solid discs, calipers, brake pads, rotors
Brake System General:
ABS (Anti-lock Braking System) components, master cylinder, brake lines, bleeding procedures
Electrical System:
Wiring diagrams, alternator, starter, battery, fuses, relays
Lighting System:
Headlights, taillights, interior lights, bulb replacement
Climate Control:
HVAC system, blower motor, heater core, A/C compressor, refrigerant handling
Bodywork Interior:
Seats, door panels, dashboard, trim removal and installation
Bodywork Exterior:
Bumpers, fenders, hood, trunk lid, door alignment
Glass Seals:
Windshield, side windows, rear window, weatherstripping
Routine Maintenance:
Oil changes, filter replacements, tune-ups, fluid checks
Engine Repair:
Head gasket replacement, piston ring installation, valve adjustments, timing belt replacement (if applicable, though M20 typically has a chain)
Fuel System Diagnostics:
Injector testing, fuel pressure checks, troubleshooting injection system faults
Transmission Overhaul:
Manual transmission clutch replacement, automatic transmission servicing and minor repairs
Suspension Component Replacement:
Strut replacement, control arm bushing renewal, ball joint inspection/replacement
Brake System Maintenance:
Brake pad/rotor replacement, brake fluid flush and bleed, caliper service
Electrical Troubleshooting:
Diagnostic procedures for electrical faults, using wiring diagrams
HVAC System Repair:
Refrigerant handling, compressor replacement, blower motor diagnosis
Body Panel Repair:
Panel alignment, rust repair guidance (general), trim replacement
Troubleshooting Guides:
Diagnostic flowcharts for common problems
Torque Specifications:
Precise torque values for all critical fasteners
Special Tools:
Identification of necessary specialized BMW tools
Depth:
Comprehensive, from basic maintenance to major component overhaul and diagnostics
Diagnostic Capabilities:
Detailed diagnostic procedures and troubleshooting steps for electrical and mechanical systems
Rebuild Procedures:
Includes guidance for engine and transmission component rebuilding
Oil Change:
Every 5,000-7,500 miles or 12 months, whichever comes first (check manual for exact recommendations based on driving conditions).
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on conditions.
Spark Plug Replacement:
Every 30,000-60,000 miles (depending on plug type used).
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles.
Brake Fluid Flush:
Every 2 years (critical for performance and ABS).
Timing Component Inspection:
The M20 engine uses a timing chain, not a belt, which typically requires inspection for wear rather than periodic replacement, but guides and tensioners can wear.
Engine Oil:
API SF or SG, SAE 20W-50 or 10W-40 (refer to manual for optimal choice based on climate and wear).
Coolant:
BMW-approved antifreeze/coolant concentrate mixed 50/50 with distilled water. Typically a phosphate-based coolant for this era.
Brake Fluid:
DOT 3 or DOT 4.
Transmission Fluid Manual:
GL-4 gear oil (e.g., 75W-90).
Transmission Fluid Automatic:
Dexron II or equivalent (check manual for specific specification).
Power Steering Fluid:
ATF Dexron II or equivalent.
Cooling System:
Cracking plastic coolant expansion tanks, water pump failure, thermostat sticking.
Fuel System:
Fuel pump relays failing, injector seal leaks, cold start valve issues.
Suspension:
Worn rear trailing arm bushings (RTABs), worn control arm bushings, sagging front springs.
Electrical:
Corroded grounds, failing headlight relays, intermittent dashboard warning lights, OBC (On-Board Computer) faults.
Interior:
Cracked dashboard (especially under sunlight), deteriorating seat foam, sagging headliner.
Rust:
Common areas include wheel arches, rocker panels, battery tray, and strut towers.
