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WIRING DIAGRAMS Fig. 3: Computer Engine Control (535i),Throttle SW (Grid 8-11)
1992 BMW 525i

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BMW 5 Series from 1989 to 1995. The aim throughout this manual has been simplicity, clarity and completeness, with practical explanations, step-by-step procedures and accurate specifications. Whether you’re a professional or a do-it-yourself BMW owner, this manual will help you understand, care for and repair your E34 5 Series.

Models and engines covered:
525i (M20 with DME 1.3) 1989-1990
525i (M50 with DME 3.1) 1991-1992
525i (M50TU/VANOS with DME 3.3.1) 1993-1995
530i (M60 with DME 3.3) 1994-1995
535i (M30 with DME 1.3) 1989-1993
540i (M60 with DME 3.3) 1994-1995
Transmissions covered:
Manual (remove, install, external service)
Getrag 260/5 and 260/6
Getrag S5D 250G
Getrag S6S 560G
Automatic (remove, install, external service)
ZF 4HP22/EH
A4S 310R (THM-R1)
ZF A5S 310Z
ZF A5S 560Z

BMW 3/5 Series 1982-1992 Auto Repair Manual
Provides service, repair and maintenance information for 3/5 Series. 318i (1984-1985), 325, 325e and 325es (1984-1988), 325i, 325is and 325ic (1987-1990), 525i (1989-1990), 528e (1982-1988), 533i (1983-1984), 535i and 535is (1985-1992)

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Much has been written about swapping Suzuki’s G16B 1.6 liter 16-valve engine into the Samurai. It is mechanically very simple (as engine swaps go) but the wiring can be a daunting challenge for many. To date it has been necessary for the DIY builder to perform extensive research, gather all the information they can find, try to make sense of it, and take their best shot (or pay someone that has already done it). There is no one “correct” way to make this engine swap. The variations are nearly endless. Much of it involves personal preference. What is presented here is a process that is known to be successful, along with some of the more familiar options. ALL WIRING SHOULD BE DONE WITH THE BATTERY REMOVED FROM THE VEHICLE 1.1. It is HIGHLY RECCOMMENED that you purchase the appropriate Field Service Manual for your engine model year (either digital or print copy). Though there are only two sections that are relevant to a transplanted engine the information is absolutely invaluable. Much – but not all – of the required Information is also available in most aftermarket vehicle specific service manuals (Haynes, Chilton’s, etc.) The pertinent sections (6 & of the 1996 Tracker FSM may be downloaded for free from Acksfaq.com (donations are appreciated). 1.2. 1992 through 1998 Suzuki/Geo (GM) vehicles with G16B (1.6 liter 16-valve) engines can be identified by the 8th digit in the Vehicle Identification Number. “0” for Suzuki badged vehicles, “6” for Geo’s (“U” indicates an 8-valve 1.6L). 1.3. The most common set-up, and arguably the simplest, mates a donor Tracker or Sidekick engine, with the Samurai 5- spd Manual Transmission. Donor engines with Automatic Transmissions (3 or 4 A/T) are easily rewired to work with the Samurai 5-spd M/T. Specific notations for installing the donor engine with a 3 A/T appear where necessary. The 4 A/T is significantly more complicated and is not included in these instructions. 1.4. It is preferred (but not required) that the ECM and engine be of the same model year. However, as long as the computer has all the necessary inputs and outputs it makes no difference what motor it is physically controlling. It should be noted that OBD1 vehicles (1995 & earlier) are much less complex than OBD2 vehicles (1996 & after). The earlier technology is far easier for the amateur auto electrician to manage. OBD2, being more modern, has nearly twice as many sensors & controls. Properly tuned, OBD2 engines will provide slightly more power, better fuel economy, and cleaner emissions. Replacement parts are also easier to find, but of course, are more expensive.

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ACCESSORIES & ELECTRICAL CHARGING SYSTEM TROUBLE SHOOTING Alternator Light Stays Off With Ignition Switch ON Blown fuse See WIRING DIAGRAMS Defective alternator Defective indicator light bulb or socket  Alternator Light Stays OFF With Ignition Switch ON Short in alternator wiring See Testing in ALTERNATOR article See Indicator Warning Lights in STANDARD INSTRUMENTS in the ACCESSORIES & EQUIPMENT section See On-Vehicle Tests in ALTERNATOR article Defective rectifier bridge Defective alternator wiring  Lights or Fuses Burn Out Frequently  Ammeter Gauge Shows Discharge Defective regulator Defective battery Loose or worn drive belt Noisy Defective wiring Defective alternator or regulator Defective ammeter, or improper ammeter wiring connection Loose drive pulley See Bench Tests in ALTERNATOR article See On-Vehicle Tests in ALTERNATOR article See Regulator Check in ALTERNATOR article Check and replace as necessary Check alternator drive belt tension and condition. See Belt Adjustment in TUNE-UP article in the TUNE-UP section Check all wires and wire connections See Bench Tests and On-Vehicle Tests in ALTERNATOR article See Testing in STANDARD INSTRUMENTS in the ACCESSORIES & EQUIPMENT section Tighten drive pulley