Clutch 2...

210-1

General
This repair group covers replacement
of the clutch mechanical and hydraulic
components. Read the procedure
through before beginning a job.

Note:

See 200 Transmission–General for

transmission application information.

Special tools

The 3 Series BMW employs a

traditional style clutch layout with a self

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adjusting clutch for manual
transmission cars. BMW suggests
some specific tools for fitting and
removing the self adjusting clutch
(SAC) assembly. These tools are
required for aligning and assembling
the clutch disk, as well as locking the
flywheel in place and aligning the SAC
assembly to the dual mass flywheel.

Flywheel locking tool BMW 11 2 170

Pilot bearing removal tool BMW 11 2

340

Pilot bearing installation tool BMW 11 2

350

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Clutch lining gauge BMW 21 2 080

Clutch centering mandrel BMW 21 2

142

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SAC clutch lock tool BMW 21 2 150

Clutch diaphragm tensioning too BMW

21 2 160

SAC tensioning tool BMW 21 2 170

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SAC locating ring BMW 21 2 180

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210-2

Clutch Hydraulics
The clutch is hydraulically actuated by
the master and slave cylinders. Clutch
disc wear is automatically taken up
through the self adjusting pressure
plate springs, making periodic
adjustments unnecessary.

A soft or spongy feel to the clutch

pedal, long pedal free-play, or grinding
noises from the gears while shifting
can all indicate problems with the
clutch hydraulics. In these
circumstances it is best to start with a
clutch fluid flush, followed, if
necessary, by replacement of the

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hydraulic parts.

Note:

The clutch hydraulic system shares the

fluid reservoir and fluid with the brake
hydraulic system.

Clutch hydraulic system,

bleeding and flushing

If the clutch/brake fluid is murky or

muddy, or has not been changed
within the last two years, the system
should be flushed. Flushing the old
fluid from the clutch lines is done using
a brake system pressure bleeder.

- Raise and safely support vehicle.

- Remove under transmission

splash guard if applicable.

- Remove brake fluid reservoir cap.

Using a clean syringe, remove
brake fluid from reservoir. Refill
reservoir with clean DOT 4 brake
fluid.

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Attach pressure brake bleeder to fluid

reservoir and pump bleeder a few times
to pressurize hydraulic fluid system.

CAUTION!

Do not exceed 2 bar (29 psi)

pressure at the fluid reservoir
when bleeding or flushing the
hydraulic system.

Brake fluid is poisonous, highly

corrosive and dangerous to the
environment. Wear safety
glasses and rubber gloves when
working with brake fluid. Do not
siphon brake fluid with your

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mouth. Immediately clean away
any fluid spilled on painted
surfaces and wash with water,
as brake fluid will remove paint.

Always use new brake fluid from

a fresh, unopened container.
Brake fluid will absorb moisture
from the air. This can lead to
corrosion problems in the
hydraulic systems, and will also
lower the brake fluid's boiling
point. Dispose of brake fluid
properly.

Connect a length of hose from clutch

slave cylinder bleeder valve (arrow) to
a container.

- Open bleeder valve and allow

brake fluid to expel until clean
fluid comes out free of air
bubbles.

- Close bleeder valve and

disconnect pressure bleeding
equipment from fluid reservoir.
Hose on bleeder valve remains
connected.

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- Slowly operate clutch pedal about

10 times. Fill reservoir with clean
fluid as necessary.

- Unbolt slave cylinder from

transmission. Fit BMW special tool
21 5 030. Press slave cylinder
pushrod completely into slave
cylinder.

- Hold slave cylinder so that bleeder

valve is at the highest point.

- Open bleeder valve.

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Once brake fluid appears with out
air bubbles, withdraw pushrod
completely.

Press slave cylinder pushrod all

the way in.

If brake fluid appears without air

bubbles close bleeder valve and
slowly release pushrod. Repeat
procedure until fluid runs out clear
and without bubbles.

- Disconnect bleeder hose. Install

slave cylinder to transmission. Add
clean brake fluid to reservoir as
necessary. Check clutch
operation.

Tightening torque
Clutch slave
cylinder to
transmission 22 Nm (16 ft-lb)

Clutch master cylinder,

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replacing

The clutch master cylinder is mounted

to the pedal assembly directly above
the clutch pedal.

- Disconnect negative (-) cable from

battery.

CAUTION!

Prior to disconnecting the battery,

read the battery disconnection
cautions given at the front of this
manual on page viii.

- Raise and safely support vehicle.

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- Remove under transmission
splash guard if applicable.

- Remove brake fluid reservoir cap.

Using a clean syringe, remove
brake fluid from reservoir.

- Disconnect fluid supply hose from

brake master cylinder. Place a
pan under hose to catch any
excess fluid.

- Working in engine compartment,

disconnect fluid line fitting from
master cylinder.

Working at left rear of engine

compartment:

Peel rubber edge seal off top of

panel.

Twist plastic panel retainers

(arrows) 90° and pull out to
remove.

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Disengage panel from hoses and

wiring harnesses and remove from
engine compartment.

Separate brake booster vacuum

hose at one way valve (A). Plug
hose ends.

- Disconnect clutch pedal from

clutch master cylinder push rod by
removing securing pin.

Remove master cylinder mounting

bolts (arrows).

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Remove clip (arrow) retaining hydraulic
line to master cylinder. Be prepared to
catch any excess brake fluid remaining
in hydraulic line.

Note:

Wrap clutch master cylinder with shop

rags when removing hydraulic fluid
lines from master cylinder to prevent
brake fluid spill.

- Pull hydraulic line from master

cylinder. Remove master cylinder
with supply hose.

- Installation is reverse of removal.

Fill fluid reservoir with clean fluid.

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Bleed clutch hydraulics as

described earlier. Connect
negative cable to battery last.

Tightening torques
Clutch master
cylinder to pedal
cluster 22 Nm (16 ft-lb)
Fluid line to
master cylinder or 20 + 5 Nm
slave cylinder (15 + 4 ft-lb)

Clutch slave cylinder, replacing

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- Pinch off brake fluid supply hose
to clutch master cylinder using
BMW special tool 13 3 010 or
equivalent fuel line clamp tool.

- Remove transmission splash

guard if applicable.

- Disconnect fluid hose from slave

cylinder. Place a pan under hose
to catch any excess fluid.

Remove mounting nuts (arrows) from

slave cylinder on left side of
transmission.

- Installation is reverse of removal,

noting the following:

Check for wear on slave cylinder.

Any other wear except on tip is
caused by misalignment of clutch
components.

Lightly coat pushrod tip with

molybdenum disulfide grease
(Molykote® Longterm 2 or

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equivalent).

During installation be sure

pushrod tip engages recess in
clutch release lever.

Fill fluid reservoir with clean fluid.

Bleed clutch hydraulics as

described earlier.

Tightening torques
Clutch slave
cylinder to
transmission 22 Nm (16 ft-lb)

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Fluid line to slave 20 + 5 Nm
cylinder (15 + 4 ft-lb)

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210-3

Clutch Mechanical
The transmission must be removed
from the engine to access the clutch
mechanical components. It is
recommended that the clutch disc,
pressure plate and release bearing be
replaced during a clutch overhaul. Be
sure to check the bottom of the
bellhousing for oil. If engine oil is
found, check for a faulty rear
crankshaft oil seal.

Due to the construction of the self

adjusting clutch (SAC) disc special
tools must be used when removing the
SAC style clutch. The pressure plate of

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the SAC clutch uses a wedge ring
which rotates against the diaphragm
springs to accommodate for clutch disc
wear. The wedge ring adjusts by
means of spring tension, so special
tools must be used to apply and relieve
spring tension as the clutch pressure
plate is removed and installed. For
special tools needed for clutch
replacement procedures refer to the
Special tools

Table a. Clutch disc diameter

Model Diameter
323i/Ci 228 mm (8.98
325i/Ci/xi in.)
328i/Ci 240 mm (9.45
330i/Ci/xi in.)

Clutch, removing

- On all wheel drive vehicles:

Remove transfer case. See 270
Transfer Case.

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- Remove transmission from engine.

See 230 Manual Transmission.

- Remove release bearing from

transmission input shaft.

Remove clutch release lever by pulling

away from spring clip in direction of
arrow.

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Lock flywheel in position using BMW
special tool 11 2 170 or equivalent.

Install BMW special tool 21 2 160 or 21

2 170 with feet (arrows) clamping on to
pressure plate at openings for
self-adjusting springs. Tighten down
head nut (A) to lock feet into position.

CAUTION!

Self adjusting clutch tool feet must

engage in the openings for adjusting
springs to safely remove the SAC
pressure plate.

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- Turn tool handle in until clutch

diaphragm spring is fully
tensioned.

- Remove six bolts from perimeter of

pressure plate. Remove self
adjusting clutch unit and clutch
disk.

Clutch assembly and hydraulics

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Clutch, inspecting

- Inspect clutch disc for wear, cracks,

loose rivets, contamination or

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excessive runout (warping).

Replace if necessary.

Note:

Measure the depth of clutch lining at

lining rivets. If shallowest rivet depth is
less than 1 mm (0.04 in.), replace clutch
disk.

- Inspect flywheel for scoring, hot

spots, cracks or loose or worn guide
pins. Replace flywheel if any faults
are found.

WARNING!

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If flywheel is removed from vehicle,
use new bolts during installation. The
old stretch-type bolts should not be
reused.

- Inspect transmission pilot bearing in

end of crankshaft. The bearing
should rotate smoothly without play.
If necessary, replace as described
later.

Inspect and clean release bearing lever.

Apply a thin coat of grease to release
bearing lever lubrication points (arrows).
Also, lightly lubricate clutch disc splines
and transmission input shaft splines.

Clutch, installing new pressure

plate

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New self adjusting clutch (SAC)

pressure plates come with a locking
plate installed that maintains spring
tension on the self adjusting springs.
This locking ring must not be removed
until the pressure plate is securely
installed on the flywheel with the clutch
disk in place.

Center clutch disk on flywheel using

BMW special tool 21 2 142, or an
equivalent clutch alignment tool.

Note:

The sides of a replacement clutch disk

are labelled engine side and
transmission side. Be sure to install

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clutch disk orientated in the proper
direction.

- Install self adjusting clutch pressure

plate onto dowel pins at flywheel.
Tighten each bolt one turn at a time
until pressure plate is fully seated,
and then torque to specification

Tightening torque
Clutch to flywheel
M8 (8.8 grade) 24 Nm (18 ft-lb)
M8 (10.9 grade) 34 Nm (25 ft-lb)

- Using a 14 mm allen wrench,

carefully screw out locking plate in
a clockwise direction.

- Remove BMW special tool 21 2 142

with bolt or screw enclosed with
replacement clutch disk.

Clean and inspect release bearing guide

sleeve on transmission. Install release
lever and release bearing. Bearing tabs
(A) align with contact points (B) on

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release lever.

- Install transmission. See 230

Manual Transmission.

Tightening torques
Transmission to engine (Torx bolts)
M8 22 Nm (16 ft-lb)
M10 43 Nm (32 ft-lb)
M12 72 Nm (53 ft-lb)

Clutch, installing used pressure

plate

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Note:

Before installing a used Self

Adjusting Clutch (SAC) pressure
plate, be sure to reset self adjusting
ring to the new position

Locating hooks of BMW special tool

21 2 180 must engage in openings
of SAC pressure plate

- Place self adjusting clutch pressure

plate on clean work surface. Install
special tool 21 2 180 onto pressure
plate.

- Squeeze handles of 21 2 180

together. Tighten down knurled
knobs of 21 2 180. SAC adjustment
ring is now in installation position.

- Install special tool 21 2 170 over 2

12 180 on SAC pressure plate.
Screw in handle of 21 2 170 until
diaphragm spring of SAC pressure
plate is pretensioned.

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Center clutch disk with BMW special tool

21 2 142. A comparable clutch alignment
tool may be used. Remove threaded
handle of clutch alignment tool

WARNING!

Be sure clutch disc is facing the

correct way. The disc should be
marked engine side or transmission
side.

- Mount self adjusting clutch

assembly on flywheel, noting
location of alignment pins.

- Tighten each bolt one turn at a time

until pressure plate is fully seated,

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and then torque to specification.

Tightening torque
Clutch to flywheel
M8 (8.8 grade) 24 Nm (17-ft-lb)
M8 (10.9 grade) 34 Nm (25 ft-lb)

- Unscrew handle of special tool until

load is removed from diaphragm.
Remove BMW special tool 21 2 180
from pressure plate.

- Remove clutch alignment tool from

disk.

Clean and inspect release bearing guide

sleeve on transmission. Install release
lever and release bearing. Make sure
bearing tabs (A) align with contact points
(B) on release lever.

- Install transmission. See 230

Manual Transmission.

Tightening torques

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Tightening torques
Transmission to engine (Torx bolts)
M8 22 Nm (16 ft-lb)
M10 43 Nm (32 ft-lb)
M12 72 Nm (53 ft-lb)

Transmission pilot bearing,

replacing

- Remove clutch as described earlier.

Remove transmission pilot bearing from

end of crankshaft using BMW special

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tool 11 2 340 or equivalent puller.

Press new bearing into place using

BMW special tool 11 2 350 or equivalent
driver.

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