Engine Mechanical:
Engine assembly, disassembly, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valve train, timing belt/chain replacement and adjustment.
Engine Management:
Bosch Motronic (ME) fuel injection and ignition systems, sensors, actuators, troubleshooting, ECU diagnostics.
Fuel System:
Fuel pump, fuel injectors, fuel pressure regulator, fuel tank, fuel lines, fuel filter replacement.
Cooling System:
Radiator, water pump, thermostat, hoses, coolant specifications, bleeding procedures.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipework inspection and replacement.
Transmission Manual:
Clutch assembly, clutch master/slave cylinders, transmission fluid change, internal component overhaul (Getrag 260).
Transmission Automatic:
Transmission fluid change, filter replacement, torque converter, external adjustments (ZF 4HP22).
Drivetrain:
Driveshaft, universal joints, differential, axle shafts, seals.
Suspension Front:
MacPherson struts, control arms, ball joints, sway bar, bushings, alignment specifications.
Suspension Rear:
Semi-trailing arms, shock absorbers, coil springs, bushings, alignment specifications.
Steering System:
Steering rack, tie rods, power steering pump, fluid, linkage, troubleshooting.
Brake System:
Front and rear disc brakes, calipers, pads, rotors, brake lines, master cylinder, ABS (if equipped), bleeding procedures, parking brake.
Electrical System:
Battery, alternator, starter motor, lighting system, wipers, horn, fuse box, relays, ignition switch, power windows, central locking.
Body And Frame:
Body panel removal/installation, door mechanisms, hinges, locks, interior trim, glass replacement, rust repair considerations.
HVAC System:
Heater core, blower motor, AC system (if equipped), refrigerant, control mechanisms.
Routine Maintenance:
Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant flushes, brake fluid changes, differential fluid changes.
Troubleshooting Diagnostics:
Step-by-step diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides.
Engine Rebuild:
Complete engine overhaul instructions, including torque specifications, clearances, and assembly sequences.
Transmission Repair:
Detailed instructions for internal transmission repairs and adjustments for both manual and automatic transmissions.
Suspension Component Replacement:
Replacement of struts, shocks, control arms, ball joints, bushings, tie rods.
Brake System Service:
Brake pad and rotor replacement, caliper servicing, brake bleeding, master cylinder replacement.
Electrical Component Testing:
Testing procedures for alternators, starters, ignition coils, sensors, and other electrical components using multimeters.
Wiring Diagram Interpretation:
Complete and detailed wiring diagrams for all vehicle electrical systems.
Body Repair Procedures:
Instructions for minor body repairs, panel alignment, and trim component replacement.
Technical Bulletins And Recalls:
Likely to include relevant service bulletins or recall information for the specific model year.
Depth:
Comprehensive, from basic maintenance to complete overhaul and advanced diagnostics.
Detail Level:
Includes detailed diagrams, exploded views, torque specifications, clearances, and procedural steps.
Oil Change:
Every 5,000-7,500 miles or 6-12 months, using synthetic or high-quality conventional oil. Manual will specify.
Air Filter:
Inspect every 15,000 miles, replace as needed.
Fuel Filter:
Replace every 30,000 miles or as recommended.
Spark Plugs:
Replace every 30,000 miles (e.g., Bosch W8AC or equivalent). Manual will specify exact type.
Timing Belt:
The M20 engine uses a timing belt. Replacement interval typically around 60,000 miles or 4-5 years. Critical to follow manual. Part number example: 11 31 1 706 212
Engine Oil:
10W-40 or 15W-40 (synthetic blend or full synthetic recommended). Oil Capacity: 4.25 L (4.5 US qt) without filter, 4.5 L (4.75 US qt) with filter.
Coolant:
50/50 mix of BMW coolant or equivalent antifreeze and distilled water. Capacity: Approx. 7.5 L (8 US qt).
Brake Fluid:
DOT 3 or DOT 4 (low-viscosity). Capacity: Approx. 1 L (1 US qt).
Common Problems:
Coolant leaks (hose connections, radiator, water pump), valve cover gasket leaks, oil pan gasket leaks, idle control valve issues, O2 sensor failure, sinking pedal in manual transmissions (clutch slave cylinder), aging rubber bushings, fuel distributor issues.