NEUTRAL SAFETY SWITCH
See Figure 1
The neutral safety switch (starter lock switch) used in the ZF type automatic transmission is combined with the reverse light switch. Therefore, if you are having problems with the reverse lights, chances are that you might have difficulty starting the car with the selector lever in PARK or NEUTRAL.
- Check the operation of the switch by disconnecting the 2 leads at terminals 50. Ground the brown terminal. Connect a 12 volt test lamp to the positive terminal and probe the second terminal tag. The test lamp should light when the selector lever is placed in P or N .
- If the switch is in need of adjustment, unscrew the switch and place correspondingly thicker seals (shims) behind the switch and the transmission housing.
See Figure 2
These adjustments are made externally. Each is made in a square headed bolt retained by a hex type locknut. Adjustment is required after the first 600 miles (966 km) and every 15,000 miles (24,000 km) thereafter.
- Loosen the locknut (1) about 1 turn (an offset hex wrench will be helpful). Tighten the adjusting bolt (2) to 50-51 ft. lbs. (65-66 Nm).
- Note the exact position of the adjusting bolts, and loosen it exactly 3 / 4 of a turn. Then, tighten the locknut.
Except 635CSi, 735i, M5, M6, 1983-84 633CSi and 733i Models
- Detach the selector rod at the selector lever lower section.
- Move the selector lever on the transmission to position O or N .
- Press the selector lever against the stop on the shift gate.
Adjust the length of the selector rod until the pin aligns with the bore in the selector lever lower section. Shorten the selector rod length by:
1 turn for 320i models
- Move the selector lever to PARK position. Loosen the nut.
- Push the transmission lever to the DRIVE or PARK position. Then push the cable rod in the opposite direction.
- Tighten the nut to 7-8 ft. lbs. (9-10 Nm).
Except 2002, 3.0, 528i, and 530i Models
- On the injection system throttle body, loosen the 2 locknuts at the end of the throttle cable and adjust the cable until there is a play of between 0.010-0.030 inches (0.2-0.8mm).
- Loosen the locknut and lower the kickdown stop under the accelerator pedal. Have someone depress the accelerator pedal until the transmission detent can be felt. Then, back the kickdown stop out until it just touches the pedal.
- Check that the distance from the seal at the throttle body end of the cable housing is at least 1.7 inches (4.3cm) from the rear end of the threaded sleeve. If this dimension is correct, tighten all the locknuts.
- Remove the air cleaner.
- Remove the accelerator cable.
- Press the accelerator pedal down to the kick down stop into the full acceleration position. In this position the throttle valve must be fully open and not extend beyond the vertical position. When adjusting, bend the stop.
- Adjust the length of the accelerator linkage using the eye bolt.
See Figure 3
- Synchronize the idle speed with the engine at operating temperature.
- Detach the linkage (1).
- Detach the accelerator cable at the operating lever (2).
- Adjust linkage so that the operating lever (2) rests on stop (3).
Make sure that linkage(1) is not pulled down into the kickdown position.
- The swivel joint (5) must align with the hole in the operating lever (2) leaving a play of 0.009-0.02 inches (0.23-0.48mm) between nipple (4) and the end of the cable sleeve.
- The accelerator must not sag. Press lever (6) against the acceleration stop (7) and adjust the linkage (8) until the distance between nipple (4) and the end of the cable sleeve is 1.4 inches (37mm). When in the kickdown position, the nipple (4) should be at least 1.7 inches (43mm) from the end of the cable sleeve.
If the idle speed is altered, repeat the above procedure.
1600, 2000 and 2002 Models
- Remove the accelerator cable from the rotary shaft.
- Press down the accelerator to the full acceleration position.
- Pull the accelerator cable to determine the full acceleration position. The holes in the fork head must coincide with the hole in the rotary selector so that the bearing pin can be inserted with correct alignment.
- Turn the fork head to adjust the cable length.
See Figure 4
- Adjust the play in (S) to 0.010-0.30 inches (0.25-0.75mm) via the adjustment nut (2) when the vehicle is in NEUTRAL.
- Press the accelerator pedal against the stop.
- Adjust the pressure rod (7) until the distance from the seal (3) to the end of the cable (4) is 1.7-2.0 inches (44-51mm).
- On the injection system throttle body, loosen the 2 locknuts at the end of the throttle cable and adjust the cable until there is a play of 0.010-0.030 inches (0.25-0.75mm).
- Loosen the locknut and lower the kickdown stop under the accelerator pedal. Have someone depress the accelerator pedal until the transmission detent is felt. Then, back the kickdown stop out until it just touches the pedal.
- Check that the distance from the seal at the throttle body end of the cable housing is at least 1.7 inches (44mm) from the rear end of the threaded sleeve. If this dimension is correct, tighten the locknuts.
See Figure 5
- Adjust the accelerator cable at nuts (1) until the accelerator cable eye (2) has a play of 0.008-0.01 inches (0.2-0.3mm).
- Depress the accelerator pedal (3) to the full throttle stop screw (4).
- There must be 0.010 inches (0.5mm) play between the operating lever (5) and stop nut (6).
- Adjust by the full throttle stop screw (4).
- Adjust the cable for zero tension with the throttle closed and accelerator pedal released.
- Loosen the locknut on the throttle stop bolt. Now adjust the bolt inward just until it suspends the accelerator pedal at the point where the throttle just reaches the wide open position. Make sure the throttle is in full detent position. Now, turn the stop screw 1 1 / 2 turns lower to get a clearance of 0.010 inches (0.5mm) between the accelerator pedal and stop bolt at full throttle. Tighten the locknut.
See Figure 6
- Adjust the free-play (S) of the cable with the transmission in the N position to 0.010-0.030 inches (0.25-0.75mm). Use cable adjuster nuts (1) to adjust the free-play.
- From inside the vehicle, loosen the kickdown switch. Screw in the kickdown stop (2) all the way in the direction of the floor pan.
- Press down on the accelerator pedal (4) to the transmission pressure point. Unscrew the kickdown stop (2) until it contacts the accelerator pedal.
- Press the accelerator to the kickdown (wide open throttle position).
- In the kickdown position, the distance should be 1.7 inches (44mm). The distance (s) equals the distance from the cable seal (5) to the end of the cable sleeve (6).
TRANSMISSION CABLE ADJUSTMENT
See Figure 5
The accelerator cable must be correctly adjusted.
- With the transmission in the NEUTRAL position, adjust the play to 0.10-0.30 inches (0.25-0.75mm) with the adjustment screw.
- Depress the accelerator pedal to kickdown stop. The play should be between 1.7-2.0 inches (43-51mm). If adjustment is needed, adjust using the screw (4).
See Figure 7
- Adjust the play in S to 0.10-0.30 inches (0.25-0.75mm). Make sure both cable locknuts are loose.
- Back off the accelerator pedal kickdown stop and depress the accelerator pedal until the transmission just reaches the detent and some resistance is felt.
- Run the kickdown stop out until it just touches the bottom of the pedal.
- Depress the accelerator through the detent and hold while measuring distance S from the lead seal to the end of the sleeve. It must be at least 1.7 inches (44mm). Adjust further, if needed.
- Tighten all locknuts.
- The engine must be at normal operating temperature so the operating lever on the injection pump rests on the idle stop. Adjust the play between the th