BMW 3 Series E90 Sedan Workshop Service Repair Manual 316i 318i 320i 320si 323i 325i 328i 330i 335i M3 M3 GTS 2004-2011 PDF - MBMW3E90OPES.zip

BMW E90 Sedan Workshop & Repair Guide — Covers All Variants (316i, 318i, 320i, 320si, 323i, 325i, 328i, 330i, 335i, M3, M3 GTS), 2004-2011

This is a full workshop and repair guide for the BMW E90 Sedan lineup, spanning every variant from the 316i through the M3 GTS. It contains the technical knowledge needed to service, troubleshoot, maintain, and fix your vehicle to the same standard as trained professionals.

BMW E90-series All Models (316i, 318i, 320i, 320si, 323i, 325i, 328i, 330i, 335i, M3, M3 GTS) Sedan MY2004-MY2011 workshop service repair manual includes:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:

Total Pages: 5,054 pages

File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)

Language: English

BMW E90-series All Models (316i, 318i, 320i, 320si, 323i, 325i, 328i, 330i, 335i, M3, M3 GTS) Repair & Service Manual 2004-2011.pdf

000 - MAINTENANCE & GENERAL NOTES....3

0 operating fluid overview....7

0000... Brake lines and connections visual inspection for leaks, damage, attachment and correct position....21

0000... CBS reset....22

0000... Check horn, headlight flashers and hazard warning flashers....25

0000... Check windscreen wash _ wipe system....26

0000... Checking coolant level and concentration, correcting if necessary....27

0000... Checking instrument _ inscription lighting, interior _ luggage compartment _ glove box lights and blower....28

0000... Checking lighting system....29

0000... Checking of road safety (test drive)....30

0000... Diagnostic brief test....31

0000... Information _ warning labels....32

0000... Resetting CBS display according to factory specification....36

0000... Seat belts Check condition of seat belt strap, check function of automatic reel, seat belt locking reel, seat belt buckle, seat belt clip and, if necessary, seat belt clasp....37

0000... Steering components Check for play, tightness, damage and wear....39

0000... Tyres checking and if necessary correcting inflation pressure, checking condition, tread depth and pattern....41

0000... Underbody incl. all visible components Check for damage, correct position, tightness, corrosion....42

0000... Vehicle care measures for inventory vehicles (new and used vehicles) as well as vehicles to be taken off the road that are in the hands of customers....43

0000... When driving on a race track....47

0000... Windscreen washer system checking fluid level, topping up if necessary....53

0000... Work instruction for removing the protective film....54

0000006 Vehicle test....56

0000009 Pre-delivery check....57

0000105 Standard scope of service....62

0000555 Interrogating fault memories in Diagnosis System....63

0000610 Service - engine oil....64

0000612 Service - front brakes....66

0000614 Service - rear brakes....67

0000616 Service - microfilter....68

0000618 Service - brake fluid....70

0000624 Service - vehicle check....71

0001... Symbols used and information in repair instructions....74

0002001 Raising the vehicle using a vehicle lift....79

0011237 Checking _ topping up oil level in automatic transmission....81

5.1.1 Axles....88

7.1.1 Installation safety of the seat belts _ seat belt buckles....91

7.1.2 Status of the seat belts _ seat belt buckles....95

7.1.3 Belt force limiter....98

7.1.4 Seat belt tensioner....99

7.1.5 Airbag....100

7.1.6 Supplementary restraint systems (SRS)....103

7.11 Odometer (if present)....104

7.12 Driving dynamics control (Electronic Stability Program, ESP) (if installed _ required)....105

Abbreviations....106

Addition to special tools cabinet All model series....110

Arguments pertaining to engine oil consumption....112

Brake fluid - Operating Fluids Specification....115

Brake fluid service ? Bonnet gas strut check with active pedestrian impact mitigation?(SA8TF)....116

CBS general - Reset is lost....118

Change to scope of maintenance work (introduction of BMW Mobility System)....119

Changed emissions test indicator BMW Condition Based Service....120

Changes in maintenance intervals (air cleaner, diesel fuel filter)....121

Complete vehicle E90....122

Emergency Services (BMW _ MINI) from issue September 2009....140

Engine oil - varying colours _ smell after initial filling in the works....141

Engine oil service - countries with higher levels of dust Check the air filter element for contamination....142

Extract from BMW Group Standard?GS?90003-2....143

FEB-FEB-NED-TESTMODULE-AKTUELL....145

General and legal information on performing the periodic exhaust-gas (emissions) test in EU countries....146

Handling the acoustic camera....152

Harmonisation of oil change intervals BMW....154

IMIB_Next....155

Ignition key data tapping on CBS vehicles....158

List of contents....164

M10 and M10 x 1 - maximum tightening torques acc. to BMW GS 90003-2....166

M12 and M12x1.5 - maximum tightening torques acc. to BMW GS 90003-2....167

M14 and M14x1.5 - maximum tightening torques acc. to BMW GS 90003-2....168

M16 and M16x1.5 - maximum tightening torques acc. to BMW GS 90003-2....169

M18 and M18x1.5 - maximum tightening torques acc. to BMW GS 90003-2....170

M4 and M5 - maximum tightening torques acc. to BMW GS 90003-2....171

M6 and M7 - maximum tightening torques acc. to BMW GS 90003-2....172

M8 and M8 x 1 - maximum tightening torques acc. to BMW GS 90003-2....173

Main group 00....174

New CBS item Pre-delivery check E60, E61, E63, E64, E65, E66, E67, E87, E90....175

New Maintenance Records service booklet and maintenance documentation All models....177

Parking brake function check - new procedure in the standard service scope _ rear brake service....179

Reduced spark plug change intervals....181

Service - vehicle check - revised maintenance scope....182

Service Sheets - Condition-based Service _ Pre-delivery Check (ISTA, ISPA, Commercial Service Data)....183

Service intervals for countries with low fuel grade (SA988 _ SA8KE, SA8KM, SA984, SA8KK, SA8KL, SA8KH, SA8KP)....185

Standard work scope - expansion of work scope (with slide _ tilt sunroof and panorama glass roof)....191

Supplement for target exhaust emissions inspection data of BMW and MINI vehicles from 04 _ 2009. Modified test specifications for petrol lean-mixture engines N43 and N53. Test procedure for hybrid vehicles....193

Test instructions for the exhaust gas test (AU) on BMW vehicles with diesel engines from European emission classification EURO 6....197

Test instructions for the exhaust gas test (AU) on BMW vehicles with petrol engines from European emission classification EURO 6....210

Test instructions for the exhaust-gas (emissions) test on BMW vehicles with petrol engines....223

Towing....233

Workshop Equipment - Planning Documentation....235

Workshop equipment sales....236

011 - ENGINE ....237

11 operating fluid overview....242

11. . . . . Equipment recoding special tool number of the transverse member for fixing the engine in the installation location....244

1100 Mounting engine on assembly stand (N55)....246

1100 Overview of tightening torques....248

1100... Engine oil consumption measurement....252

1100... Overview of consumables (Electronic Parts Catalogue)....253

1100... Service - engine oil (N55)....259

1100039 Checking compression of all cylinders (N55)....262

1100050 Removing and installing engine (N55)....266

1100300 Engine oil consumption measurement....272

1100670 Securing engine in installation position (N55)....276

1112 Overview of Technical Data....282

1112 Overview of tightening torques....285

1112000 Removing and installing _ sealing cylinder head cover (N55)....299

1112040 Removing and installing all ignition coils and injector wells (N55)....303

1112100 Removing and installing cylinder head (N55)....305

1112101 Replacing cylinder head gasket (N55)....311

1112670 Cleaning intake port with walnut shell granulate (N55)....314

1112719 Resurfacing cylinder head lower face (N55)....320

1112729 Checking cylinder head for water leaks (N55)....322

1113 Overview of tightening torques....324

1113000 Removing and installing, sealing or replacing oil sump (N55)....331

1114010 Replacing sealing cap for vacuum pump (N55)....334

1114015 Removing and installing _ replacing sealing cap for oil pump chain tensioner (N55)....337

1114151 Replacing radial crankshaft seal on transmission side (N55)....340

1121500 Replacing crankshaft (N55)....345

1121505 Seal lower section of crankcase (N55)....355

1121531 Replacing all crankshaft main bearing (N55)....373

1122500 Removing and installing _ replacing flywheel (N55)....379

1123010 Removing and installing _ replacing vibration damper (N55)....382

1124571 Replacing all connecting rod bearing shells (N55)....385

1125530 Removing and installing _ replacing all pistons (N55)....389

1125671 Replacing piston rings on all pistons (N55)....397

1128010 Replacing drive belt for alternator (N55)....400

1128020 Replacing tensioning device for alternator drive belt (N55)....401

1130 Overview of tightening torques....403

1131 Overview of tightening torques....404

1131005 Checking camshaft timing (N55)....416

1131025 Removing and installing _ replacing intake camshaft (N55)....422

1131028 Removing and installing _ replacing exhaust camshaft (N55)....426

1131051 Replacing timing chain (N55) from March 2012....436

1131051 Replacing timing chain (N55) up to March 2012....443

1131090 Installing and removing _ replacing chain tensioner piston (N55)....450

1131505 Adjusting timing of camshaft(s) (N55)....452

1133050 Removing and installing _ replacing all rocker arms (N55)....457

1134552 Removing and installing _ replacing all valves (N55)....460

1134560 Replacing all valve stem seals (N55)....462

1134715 Replacing all valve springs (N55)....464

1136 Overview of tightening torques....468

1136046 Removing and installing _ replacing the intake and exhaust camshaft adjusters....472

1136046 Removing and installing or replacing intake and exhaust camshaft adjusters (N55)....515

1136655 Removing and installing _ replacing both solenoid valves (N55)....520

1137 Overview of tightening torques....523

1137... Fault patterns, valve gear (N20 _ 26 _ N55)....526

1137005 Removing and installing _ replacing eccentric shaft (N55)....529

1137010 Removing and installing _ replacing intermediate levers (N55)....532

1137020 Removing and installing _ replacing servomotor for eccentric shaft (N55)....544

1140000 Checking engine oil pressure (N55)....551

1141000 Removing and installing _ replacing oil pump (N55) from March 2012....556

1141000 Removing and installing _ replacing oil pump (N55) up to March 2012....561

1141010 Removing and installing _ replacing chain module for oil pump _ vacuum pump (N55) from March 2012....565

1141010 Removing and installing _ replacing chain module for oil pump _ vacuum pump (N55) up to March 2012....574

1141115 Removing and installing _ replacing hydraulic valve (N55)....583

1142 Overview of tightening torques....585

1142020 Removing and installing _ replacing full-flow oil filter (N55)....598

1142035 Removing and installing _ replacing the thermostat housing N55....600

1151000 Removing and installing _ renewing coolant pump (N55)....602

1153 Overview of tightening torques....606

1153000 Removing and installing _ replacing coolant thermostat (N55)....613

1161 Overview of tightening torques....615

1161050 Removing and installing intake plenum (N55)....623

1165 Overview of tightening torques....627

1165020 Removing and installing _ replacing exhaust turbocharger (N55)....640

1166000 Removing and installing _ replacing vacuum pump (N55) from March 2012....648

1166000 Removing and installing _ replacing vacuum pump (N55) up to March 2012....651

1178510 Replacing oxygen control sensor (N55)....653

1178610 Replacing lambda oxygen monitoring sensor (N55)....659

6.1.9 Engine performance....661

9.0 BMW Longlife-17 FE+....662

BMW Quality Longlife-04 All....664

Camshaft....665

Cleaning the cylinder head intake ports and the combustion chamber with the walnut blaster....666

Connecting Rods and Bearings, BMW, N55, B30....667

Connecting Rods and Bearings....668

Coolant pump with drive....669

Crankshaft and Bearings, BMW, N55, B30....670

Crankshaft and Bearings....675

Cylinder Head with Valve Seat Cover, BMW, N55, B30....677

Cylinder head with cylinder head cover....678

Cylinder head with lid, BMW, N55, B30....679

Emissions control, control sensor _ monitoring sensor....680

Emissions-control, Lambda oxygen sensor....681

Engine Block, Cylinder Crankcase, BMW, N55, B30....682

Engine block....683

Engine identification....685

Engine in general, BMW, N55, B30....695

Fan....696

Flywheel....697

Intake camshaft, BMW, N55, B30....699

Intake manifold....700

Leak-testing the air-intake system....702

Main group 11....705

Oil Filter and Lines....706

Oil pump with strainer and motor, BMW, N55, B30....707

Oil pump with strainer and motor....708

Oil sump....710

Oil supply, BMW, N55, B30....712

Pistons with Rings and Pins, BMW, N55, B30....713

Standard screw connection....715

Thermostat and Connections....716

Turbocharger and Control....717

V-ribbed belt with Tension and Deflection Element....718

Vacuum pump, BMW, N55, B30....719

Vacuum pump....720

Vacuum supply All models....721

Valves with Springs, BMW, N55, B30....725

Variable Camshaft Control....726

Variable valve gear....727

Vibration Damper....728

Vibration damper, BMW, N55, B30....729

012 - ENGINE ELECTRICAL SYSTEM....730

12.... Removing and installing _ replacing ignition coil cover (N55)....732

12.... Removing and installing _ replacing rear ignition coil cover (N55)....733

1200 Contents of the motor electronics, general....735

1200... Instructions for removal and replacement of control units....736

1200... Instructions for working on the ignition system....738

1212011 Removing and installing _ replacing all spark plugs (N53, N54, N54T, N55, N63, S63)....740

1213511 Replacing ignition coils (N55)....743

1214521 Replacing crankshaft pulse sensor (N55)....746

1214523 Replacing pulse sensor on intake camshaft (N54, N54T, N55)....748

1214524 Replace pulse sensor on exhaust camshaft (N54, N54T, N55)....750

1214550 Replacing control unit (DME) (N55)....752

1214600 Removing _ replacing knock sensors (N55)....755

1214650 Replacing differential-pressure sensor on intake plenum (N55)....760

1214651 Replace the pressure sensor on the charge air duct (N54, N54T, N55)....762

1214700 Encoding the control unit (DME _ DDE)....764

1214705 Programming the control unit (DME _ DDE)....765

1231009 Checking alternator (BSD)....766

1231020 Removing and installing or replacing alternator (N54, N54T, N55)....770

1232501 Replacing voltage regulator....772

1241020 Removing and installing _ replacing starter motor (N54, N54T, N55 )....776

1241041 Replacing the engagement solenoid switch....777

1242500 Replacing positive battery cable between starter motor, alternator and positive battery connection point (N54 N54T N55 )....779

1251001 Replacing wiring harness section for engine (N55)....781

1251100 Replacing wiring harness section for ignition and injectors (N55)....786

1261280 Removing and installing _ replacing oil pressure sensor (N55)....788

1261285 Removing and installing _ renewing oil level sensor for engine oil (N55)....790

1290 Overview of tightening torques....792

1290... Removing and installing _ replacing electronics box....794

1290100 Replacing fan for electronics box....799

Alternator lead....801

Alternator with Drive and Mounting Parts....802

Electronic Shift Units or Control Units....803

Electronics box, wiring harness (N55)....804

Engine oil pressure, engine oil temperature, oil condition display....805

Spark Plugs....806

Starter motor with mounting....807

013 - FUEL PREPARATION & CONTROL....808

1161365 Removing and installing _ replacing front left charge air duct (N55)....810

1161368 Removing and installing _ replacing rear left charge-air duct (N55)....812

13 operating fluid overview....814

1300 Overview of tightening torques....815

1331... Notes regarding the fuel pressure test (reference pressure surrounding area)....816

1331032 Check fuel pressure....818

1351017 Removing and installing _ replacing high pressure pump (Bosch) (N55)....823

1351017 Removing and installing _ replacing high pressure pump (Continental) (N55)....827

1353 Overview of tightening torques....838

1353... Remove, install replace one injector N55 as from engine number 14407685 (hold-down device concept at the top)....851

1353... Removing and installing _ replacing an injector N55 up to engine number 14407684 (bottom hold-down device version)....862

1353... Warnings for the removal of injectors?(N55)....874

1353158 Removing and installing _ replacing rail (Bosch high pressure pump) (N55)....877

1353158 Removing and installing _ replacing rail (Continental high-pressure pump) (N55)....883

1353158 Removing and installing _ replacing rail (rail with pressure lines) (N55)....890

1353192 Removing and installing _ replacing a pressure line (Bosch high-pressure pump) (N55)....894

1353192 Removing and installing _ replacing a pressure line (Continental high-pressure pump) (N55)....899

1353310 Removing and installing _ replacing an injector (N55)....904

1353332 Removing and installing _ replacing feed line (Bosch high pressure pump) (N55)....906

1353332 Removing and installing _ replacing feed line (Continental high pressure pump) (N55)....910

1353334 Removing and installing _ replacing pressure line (Bosch high-pressure pump) (N55)....915

1353334 Removing and installing _ replacing pressure line (Continental high pressure pump) (N55)....919

1353596 Replacing high-pressure fuel sensor (N55)....927

1354030 Removing and installing _ sealing throttle body (N55)....933

1362531 Replacing coolant temperature sensor (N55)....935

1362560 Removing and installing _ replacing hot film air mass meter (N55)....937

1362582 Removing and installing _ replacing oil temperature sensor (N55)....939

1371 Overview of tightening torques....941

1371000 Removing and installing _ replacing intake silencer housing (N55)....951

1371150 Removing clean air pipe (N55)....953

1371170 Removing air duct (N55)....955

1372001 Replacing air filter element (N55)....956

1390500 Replacing tank vent valve (N55)....958

Fuel Injector Nozzles and Lines....960

Group 13....962

Intake muffler....963

Sensors for control unit....964