AC mounting BMW 328i 1997 E36 Repair Manual

7
.
Unbolt
timing
chain
casefrom
frontof
engine
.
See
Fig
.
13
.



9
.
Installation
is
reverse
of
removal
.

Fig
.
13
.
Timing
chain
case
mounting
bolts
(arrows)
on
M44
engine
.

8
.
Remove
cover
from
oil
pump
on
rear
of
timing
chain

case
.
See
Fig
.
14
.
Inspect
oil
pump
gears
and
oil
pump

cavity
in
timing
chain
case
for
wear
andlor
scoring
.

Fig
.
14
.
Oil
pump
cover
mounting
bolts
(arrows)
on
M44
engine
.

LUBRICATION
SYSTEM



119-
9

"
Replace
al¡
gaskets
and
O-rings
.
"
Install
a
new
rubber
sea¡
(profile
gasket)
between
top
of
timing
chain
case
and
cylinder
head
.

"
Be
sure
to
thoroughly
clean
sealing
surfaces
.
-Use
3-Bond
1209
orequivalent
sealant
on
both
sides

of
sea¡
before
installing
.

10
.
Protect
profile
gasket
using
thin
sheet
metal
(BMW
special
tool
no
.
11
2
330)
when
installing
timing
chain

case
.
See
Fig
.
15
.

"
Applya
thin
coating
of
grease
to
both
sides
of
sheet
metal
tool
and
to
top
surface
of
profile
gasket
.

"
Placesheet
metal
between
gasket
and
cylinder
head

and
carefully
slíde
upper
chain
cover
into
position
.

"
Tighten
al¡
mounting
bolts
and
then
carefully
withdraw

sheet
metal
.
Install
timing
chain
as
described
in
117

Camshaft
Timing
Chain
.

Fig
.
15
.
Use
thin
sheetmetal
(arrow)
toprotect
profile
gasket
during
installation
of
timing
chain
case
.
Carefully
withdraw
sheetmetal
after
tightening
fasteners
.

Tightening
Torques

"
Timing
chain
case
to
engine
block

M6
..
.
...
...
.
..
.............
.
.10
Nm
(7
.5
ft-Ib)

M8
........
.
..
..
..............
22
Nm
(16
ft-Ib)

"
Thermostathousing
to
upper

timing
chain
cover(M6)
............
10
Nm
(89
in-lb)

"
OH
filter
cover

to
oil
filter
housing
(M8)
.
.
.........
25
Nm
(18
ft-lb)

"
Oil
pump
cover
to
timing
chain
case
(M6)
...
..
.......
10
Nm
(89
in-lb)

"
Oil
pan
to
engine
block
(M6
bolt)

8
.8
grade
.........
.
.
..
.........
10
Nm
(89
in-lb)

10
.9
grade
............
.
.......
12
Nm
(106
in-lb)

"
Alternator
to
alternator
bracket
.....
43
Nm
(32
ft-Ib)

OIL
PUMP

119-
1
0



LUBRICATION
SYSTEM

Oil
pump,
removing
and
installing

(6-cylinder
engine)

Oil
pressure
on
the
6-cylinder
engines
is
generated
by
a
gear-type
pump
bolted
to
the
bottom
of
the
engine
block
.
The
oil
pump
is
chain
driven
off
the
front
of
the
crankshaft
.

NOTE-

Oil
pump
removal
requires
raising
the
engine
(cars
built
up
to
9-92)
or
lowering
the
front
suspension
crossmem-
ber
(cars
built
from
9-92)
to
remove
the
oil
pan
.

1.
Drain
oil
as
described
in
020
Maintenance
Program
.

2
.
Remove
oil
pan
as
described
earlier
.

3
.
Remove
oil
pump
sprocket
mounting
nut
(left-hand
thread)
.
See
Fig
.
16
.
Lift
sprocket
off
together
with
drive
chain
.

Fig
.
16
.
Oil
pump
sprocket
mounting
nut
(left-hand
thread)
on
6-cylin-
der
engine
(arrow)
.

4
.
Remove
mounting
bolts
from
oil
pump
and
oil
pump
pickup
tube
.
Withdraw
pump
.

NOTE-

Note
any
spacers
between
pump
and
engine
block
.
See
Fig
.
17
.

"
Note
position
of
locating
dowels
.

OIL
PUMP

811186

0011952

Fig
.
17
.
Oil
pump
mounting
points
(1)
and
pickup
tube
mountíng
points
(2)
.

5
.
Remove
coverfrom
oil
pump
and
check
for
wear
or
scoring
.
Spin
oil
pump
shaft
and
check
that
gears
turn
smoothly
.
Replace
pump
if
gears
spinwith
difficulty
or
any
wear
is
present
.

6
.
Installation
is
reverse
of
removal,
noting
the
following
:

"
Align
sprocket
splines
to
oil
pump
shaft
splines
before

tightening
sprocket
nut
.

Tightening
Torques

"
Oil
pump
to
engine
block
(M8)
......
22
Nm
(16
ft-Ib)

"
Oil
pan
to
engine
block
(M6
bolt)

8
.8
grade
..
...
.
...
...
.
.........
10
Nm
(89
in-lb)

10
.9
grade
.
...
.
..
....
.
........
12
Nm
(106
in-lb)

"
Oil
pump
sprocket
to
oil
pump
shaft
(M1
0x1
left-hand
thread)
..........
25
Nm
(18
ft-Ib)

120-
4



IGNITION
SYSTEM

2
.
Check
for
battery
voltage
o
cofs
.
If
voltage
is
not



Table
b
.
Ignition
Coil
Resistance

present,
check
wire
between
terminal
15
and
ignition



(M42
Engine)
switch
.
See
Electrical
Wiring
Diagrams
.

"
On
M42
engine,
connect
digital
multimeter
between
ter-

minal
15(+)
in
each
harness
connector
and
ground
.
See

Fig
.
4
.

"
On
M44
engine,
connect
voltmeter
between
terminal
2

(15+)
in
connector
and
ground
.
Turn
ignition
on
and

check
for
voltage
.
See
Fig
.
5
.

3
.
Turn
ignition
off
.

0
4a15

Fig
.
4
.



Ignition
coil
harness
connector
terminal
identification
for
M42

engine
.

Fig
.
5
.



Ignition
coil
harness
connector
terminal
identification
for
M44
engine
.

CAUTION-

The
wiring
to
the
coil(via
the
ignition
switch
15+)
is
not
fuse
protected
.
Use
care
when
testing
thiscircuit
.

4
.
Use
a
digital
multimeter
totest
coil
primary
resistance
.

"
On
M42
engine,
use
Table
b
asa
guide
to
check
coil

resistance
.
Make
checks
at
each
harness
connector
.

"
On
M44
engine,
use
Table,c
as
a
guide
to
check
coil
primary
resistance
.

5
.
Inspect
coil
housing
for
hairline
cracks
or
leaking
cast-
ing
material
.
See
Fig
.
7
.
A
leaky
ignition
coil
may
indi-



11502

cate
a
faulty
ECM
(engine
control
module)
.
Check
the
ECM
before
installing
a
new
coil
.



Fig
.
6
.



Ignition
coil
harnessconnector
terminal
identification
for
6-
cylinder
engine
.

IGNITION
SYSTEM
SERVICE

11502

Terminals
Resistance
(refer
to
Fig
.
4
.)

Coil
primary



1
(-)
and
15
(+)



10
.4-0
.8
ohms

Coil
secondary



N
.A
.



N
.A
.

Table
c
.
Ignition
Coil
Resistance

(M44
Engine)

Terminais
Resistance
(referto
Fig
.
5
.)

Coil
#1
primary



1
(-)
and
2
(+)



0
.4-0
.8
ohms

Coil
#2
primary



6
(-)
and2
(+)



0
.4-0
.8
ohms

Coil
#3
primary



7
(-)
and
2
(+)



0
.4-0
.8
ohms

Coil
#4
primary



5
(-)
and2
(+)



0
.4-0
.8
ohms

Coil
secondary



N
.A
.



N
.A
.

NOTE-

If
a
single
coilís
faulty
on
M44
engines,
the
complete
coil
pack
will
have
to
be
replaced
.

Ignition
coil,
testing
and
replacing

(6-cylinder
engine)

CAUTION-

Use
a
digital
multimeter
for
the
following
tests
.

1.
Remove
plastic
enginecovers
from
top
of
engine
by

prying
off
nut
covers
and
removingcover
mounting

nuts
.
See
113
Cylinder
HeadRemoval
and
Installa-

tion
.

2
.
Disconnect
harnessconnectorfromcof
.
Connect
mul-
timeter
between
terminal
15
(+)
in
connector
and

ground
.
See
Fig
.
6
.

3
.
Turn
ignition
on
and
check
for
batteryvoltage
.

"
If
batteryvoltage
is
not
present,
check
wire
between

terminal
15
and
ignition
switch
.
See
Electrical
Wiring

Diagrams
.

"mozo

120-
6



IGNITION
SYSTEM

Crankshaft
position/rpm
sensor,

testing
and
replacing
(front
mounted)

1
.
Disconnect
sensor
harness
connector
.

2
.
Using
a
digital
multimeter,
check
resistance
between
terminals
1
and
2
in
connector
.
See
Fig
.
10
.

n1
n2n3

Fig
.
10
.
Crankshaft
position/rpm
sensorconnector
.

Crankshaft
positionlrpm
sensor
specifications

"
Coil
resistance
(approx
.)
terminais
1
and
2
....
.
..
...
....
1280
±
10%
ohms

"
Air
gap
(sensor
distance
from
toothed
wheel)
..
.
.
........
.1
.0
±
0
.3
mm
(0
.04
±
0
.01
in
.)

3
.
If
the
resistance
is
not
correct,
the
sensor
is
faulty
and
should
be
replaced
.

NOTE
-

When
installing
the
new
sensor,
be
sure
thewiring
Is
rerouted
in
the
same
orientation
.
Secure
the
sensor
us-
ing
new
wire
ties
.

Tightening
Torque

"
Crankshaft
position/rpm
sensor
to
mounting
bracket
.........
.
.
5
t
1
Nm
(62
t
9
in-lb)

Crankshaft
position/rpm
sensor,



4
.
Installation
is
reverse
of
removal
.
Use
a
new
O-ring
replacing
(rear
mounted)



when
installing
sensor
.
Be
sure
wiring
is
rerouted
in
same
orientation
.
1
.
Disconnect
sensor
harness
connector
.

6502AGN56

2
.
Locatesensor
on
rear
left
sideof
cylinder
block
.
Re-
move
sensormounting
bolt
and
remove
sensorfrom
cylinder
block
.

IGNITION
SYSTEM
SERVICE

3
.
Installation
is
reverse
of
removal
.
Use
a
new
O-ring

when
installing
sensor
.
Be
sure
wiring
is
rerouted
in
same
orientation
.
Secure
sensor
using
new
wire
ties
.

NOTE-

It
may
be
easier
to
remove
the
sensor
working
from
the
underside
of
the
vehicle
.

Camshaft
Position
(CMP)
Sensor

The
camshaft
position
(CMP)
sensor
is
usedby
the
engine
management
system
for
sequential
fuel
injection
and
knock
control
.

Camshaft
position
(CMP)
sensor,

replacing
(4-cylinder
engine)

1
.
Remove
CMP
sensorfromtop
timing
cover,
just
above
coolantthermostat
housing
.
See
Fig
.
11
.

Fig
.
11
.
Camshaft
position
sensor
mounting
bolt
(arrow)
.
M42
engine
shown
.

2
.
On
M42
engines
to
9/93
:
Disconnect
CMP
harness
plug
just
above
oil
filter
housing
.

3
.
On
M42
from9/93
and
all
M44
engines
:
Remove
upper
intake
manifold
as
described
in
113
Cylinder
Head
Re-
moval
and
Installation
.
Then
unplug
CMP
sensor
har-
ness
connector
below
manifold
.

Camshaft
position
(CMP)
sensor,

replacing
(6-cylinder
engine)

1
.
Remove
plastic
cover
from
above
fuel
injectors
.

2
.
Disconnect
harness
connector
from
VANOS
solenoid

and
unscrew
solenoid
from
VANOS
control
unit
.
Re-



"
Clean
contactsurface
on
engine
block
before
fnstall

move
oil
supply
line
from
VANOS
control
unit
.
See
117



ing
knock
sensors
.

Camshaft
Timing
Chain
.

3
.
Remove
camshaft
position
(CMP)
sensor
from
left
frontof

cylinder
head,
next
to
top
of
oil
filter
housing
.



"
Knock
sensor
to
cylinder
block
....
20
Nm
(15
ft
.
lbs
.)

4
.
Disconnect
CMP
sensor
harnessfrom
under
intake

manifold
.

5
.
Installation
is
reverse
of
removal
.
Use
a
new
O-ring

when
installing
sensor
.
Be
sure
wiring
is
rerouted
in

same
orientation
.

Tightening
Torques

"
CMP
sensor
to
cylinder
head
....
.
.
..
5
Nm
(3
.5
ft-Ib)

"
VANOS
oil
supply
pipe
to

VANOS
control
unit
...........
.
..
32
Nm
(24
ft-Ib)

"
VANOS
solenoid
to
VANOS

control
unit
...
.
.................
30
Nm
(22
ft-Ib)

Knock
sensors,
replacing

Knock
sensors
are
usedon
engines
with
Bosch
DME
M1
.7,

Bosch
DME
M3
.3
.1,
Bosch
DME
M5
.2,
and
Siemens
MS
41
.1

engine
management
systems
.
The
knocksensors
are
bolted
to
the
left
sideof
the
cylinder
block
and
monitor
the
combus-

tion
chamber
for
engine-damaging
knock
.
If
engine
knock
is

detected,
the
ignition
point
is
retarded
accordingly
via
the
en-

gine
control
module
.

CA
UTION-

"
Label
knock
sensorharness
connectors
before

disconnecting
them
.
The
connectors
must
not
be

interchanged
.
Engine
damage
may
result
if
the
sensors
are
monitoring
the
wrong
cytinders
.

"
Note
the
installed
angle
of
the
knock
sensoron
the

block
before
removing
it
.
Reinstall
the
sensor
in

the
same
position
.
Be
sure
to
usea
torque
wrench

when
tightening
the
sensormounting
bola

NOTE
-

"
On
M52
engines,
a
single
harness
connects
the
twosensors
to
the
main
harness
connector
.
The
shorter
cable
lead
fs
for
the
knock
sensor
for
cytinders
4,
5,
and
6
.

Tightening
Torque

IGNITION
SYSTEM



120-
7

0012730

Fig
.
12
.
Knock
sensor
mounting
bolt
on
front
left
side
of
cylinder

block
.

NOTE-

Knock
sensor
function
Is
monitoredby
the
On-Board
Diagnostic
system
.
If
a
knock
sensor
is
detected
to
be
faulty,
an
appropriatediagnostic
trouble
code
(DTC)
may
be
stored
in
memory
.
See
100
Engine-General
for
information
on
retrieving
DTCs
.

On
6-cylinder
engines,
the
knock
sensors
are
accessible
af-
ter
removing
the
intake
manifold
.
On
4-cylinder
engines,
the

upper
section
of
the
intake
manifold
should
be
removed
to
ac-

cess
the
sensors
.
See
Fig
.
12
.
NOTE-

Intakemanifold
removal
and
installation
procedures
are



"
Cylinder
no
.
1is
at
the
front
of
the
engine
.

covered
in
113
Cylinder
HeadRemoval
and
Installation
.

Ignition
Firing
Order

Ignition
Firing
Order

"
4-cylinder
engines
.....
..
...
.
..........
.1-3-4-2

"
6-cylinder
engines
...........
..
.
.
..
..
1-5-3-6-2-4

IGNITION
SYSTEM
SCHEMATICS

Fig
.
13
through
Fig
.
17
show
ignition
system
schematics

usedon
the
enginescoveredby
this
manual
.

IGNITION
SYSTEM
SCHEMATICS

2
.
Remove
cooling
duct
or
terminal
cover
from
rear
of
al-



2
.
Remove
air
cleaner
upper
section
with
mass
air
flow
ternator
.



sensor
.

3
.
Check
for
battery
voltage
between
ground
and
terminal



3
.
Remove
terminal
cover
from
rear
of
alternator
.
Discon
B+
at
back
of
alternator
.
Then
turn
ignition
on
and



nect
wiring
.
check
for
battery
voltage
between
terminal
D+
and
ground
.
See
Fig
.
3
.
lf
voltage
is
not
present
at
either



4
.
Remove
drive
belt
from
alternator
pulley
.
See
020
point,
check
wiring
for
faults
.



Maintenance
program
.

001
¡987
Fig
.
3
.



Terminal
B+
is
supplied
battery
voltage
directly
from
the
bat-
tery
.
Terminal
D+
is
supplied
battery
voltage
via
the
charge
warning
bulb
when
thekey
is
on
or
the
engine
is
running
.

4
.
lf
no
faults
are
foundup
to
thispoint,test
alternator
out-

put
using
a
load
tester
.

5
.
If
a
load
tester
is
not
available,
a
crude
output
test
can
be
done
by
running
engine
at
about
2000
rpmand
turn-
ing
on
electrical
loads
(fans,
lights
and
rear
window
de-
froster,
wipers)
.
With
al¡
accessories
on,
battery
voltage
should
be
above
12
.0
VDC
.

A
replacement
alternator
should
have
the
same
rating
as
the
original
.
Alternator
manufacturer
and
ampere
rating
are
normally
marked
on
the
alternator
housing
.
1
.
Disconnect
negative
(-)
battery
cable
.

CAUTION-

Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
vi¡¡
.

BATTERY,
STARTER,
ALTERNATOR



121-
5

6
.
Remove
upper
and
lower
mounting
bolts
and
lift
out
al-
ternator
.
See
Fig
.
4
.

NOTE
-

If
reusing
drive
belt,
mark
direction
of
rotation
on
belt
before
removing
.

5
.
On
M44
engine
with
hydraulic
belt
tensioner
:
Remove
tensioner
idler
pulley
(upper
roller)
from
alternator

bracket
.

Fig
.
4
.



Alternator
mounting
bolts
(arrows)
.

O



u
J
S
v~~

U

I



1
i
n
-12
.22

Alternator,
removing
and
installing



7
.
Installation
is
reverse
of
removal
.
Install
drive
belt
as

(4-cylinder
engine)



described
in
020
Maintenance
Program
.

Tightening
Torques

"
D+
vire
to
alternator
(M6
nut)
.
...
.
.
.
7
Nm
(53
in-lb)

"
B+
wire
to
alternator
(M8
nut)
..
.
.
.
.
.
13
Nm
(10
ft-Ib)

"
Pulley
to
alternator
(M16
nut)
...
..
..
60
Nm
(44
ft-Ib)

ALTERNATOR
SERVICE

121-
6



BATTERY
STARTER,
ALTERNATOR

Alternator,
removing
and
installing

(6-cylinder
engine)

A
replacement
alternator
should
have
the
same
rating
as

the
original
.
Alternator
manufacturer
and
ampere
rating
are

normally
marked
on
the
alternator
housing
.

1
.
Disconnect
negative
(-)
battery
cable
.

CAUTION-

Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
onpage
viii
.

2
.
Remove
alternator
cooling
duct
and
air
filter
housing

assembly
from
car
.
Disconnect
wiring
from
rear
of
alter-

nator
.

3
.
Remove
radiator
cooling
fan
and
fan
shroud
.
See
170

Radiator
and
Cooling
System
.

4
.
Remove
alternator
drive
belt
from
alternator
pulley
.
On

engines
with
hydraulic
belt
tensioner,
remove
tensioner

idler
pulley
(upper
roller)
from
alternator
bracket
.
See

Fig
.
5
.

ALTERNATOR
SERVICE

Fig
.
5
.



Pry
off
cover
from
tensioner
and
then
lever
tensioner
clock-
wise
to
release
belt
tension
.
Remove
upper
roller
(A)
once
belt
ís
removed
.

NOTE-

If
reusing
drive
belt,
mark
direction
of
rotation
on
belt

before
removing
.

5
.
Remove
upper
and
lower
mounting
bolts
and
lift
out
al-

ternator
.

6
.
Installation
is
reverse
of
removal
.
Note
locating
notches
on
tensioner
idler
pulley
(upper
roller)
alternator
brack-

et
when
installing
pulley
.

Tightening
Torques

"
D+
wire
to
alternator
(M6
nut)
.......
7
Nm
(53
in-lb)

"
B+
wireto
alternator
(M8
nut)
.......
13
Nm
(10
ft-Ib)

"
Pulley
to
alternator
(M16
nut)
.......
60
Nm
(44
ft-Ib)

Voltage
regulator,
removing
and
installing

1
.
Disconnect
negative
(-)
cable
from
battery
.

NOTE-



2
.
Remove
alternator
as
described
earlier
.

The
radiator
cooling
fan
nut
(32
mm
wrench)has
left-
hand
threads
.



3
.
Remove
cooling
duct
from
rear
of
alternator
.
See
Fig
.
6
.

Alternator

.
.g-



p~
J

-..
.

Fig
.
6
.



Alternator
assemblyand
related
parts
.

Cooling
duct

0012524

4
.
Remove
voltage
regulator
mounting
screws
and
re-

move
regulator
from
alternator
.

5
.
Installation
is
reverse
of
removal
.
Clean
brush
contact

surfaces
in
alternator
and
check
brush
length
asde-

scribed
later
.

121-1
O



BATTERY,
STARTER,
ALTERNATOR

9
.
Remove
starter
from
above
.

10
.
Check
starter
pinion
gear
and
flywheel
teeth
for
dam-
age
.

11
.
Installation
is
reverse
of
removal
.

Tightening
Torques

"
tntakemanifold
to
cylinder
head

M7
nut
...
.
................
...
.
15
Nm
(11
ft-Ib)

M8
nut/bolt
.............
.
.
..
...
22
Nm
(16
ft-Ib)

"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-Ib)

"
Support
bracket
to
starter
(M5
nut)
...
5
Nm
(44
in-lb)

"
Support
bracket

to
engine
block
(M10
bolt)
.
.
..
..
...
47
Nm
(35
ft-Ib)

"
Wire
toterminal
50
(M6
nut)
.
..
.....
6
Nm
(53
in-lb)

"
Wire
toterminal
30
(M8
nut)
...
.....
12
Nm
(9
ft-Ib)

Solenoid
switch,
removing
and
installing

1
.
Remove
starter
as
described
above
.
Tightening
Torque

2
.
Remove
cover
from
solenoid
switch
.



"
Field
winding
strap
to
starter
(M8)
...
.
12
Nm
(9
ft-Ib)

3
.
Disconnect
fieid
winding
strap
between
starter
motor

and
solenoid
switch
.

NOTE-

The
condition
of
the
field
winding
strap
is
critical
.
If
it
is
damaged,
bumed
or
partially
melted
through,
a
new
or

rebuilt
starter
motor
is
needed
.

4
.
Remove
solenoidswitch
mounting
screws,
and
sepa-

,
rate
solenoid
from
starter
.
See
Fig
.
12
.

CAUTION-

When
installing
fieid
winding
strap
to
starter,
posi-

tion
it
so
that
it
does
not
contact
the
starter
body
.

STARTER
SERVICE

131~184

Fig
.
12
.
Starter
solenoid
mounting
screws
(arrows)
are
tight
.
Use
en
impact
screwdriver
to
loosen
the
screws
.

5
.
Installation
is
reverse
of
removal
.
Lubricate
solenoid
pistos
with
light
grease
.

6
.
Remove
fuel
rail
mounting
bolts
.
See
Fig
.
17
.

0012504

Fig
.
17
.
Location
of
fuel
rail
mounting
bolts
(A)
and
fuel
inlet
and
return
lines
(B)
on
M44
engine
.
Upper
manifold
has
been
removed
.

7
.
Pull
upon
fuel
rail
and
remove
injector
rail
with
injec-tors
.
Remove
individualinjectors
by
removing
injector

retaining
clip
and
pullinginjector
from
rail
.
See
Fig
.
18
.

Fig
.
18
.
Pry
retaining
clip
from
injector
(1),
then
pull
injector
from
rail
(2)
.

8
.
Installation
is
reverse
of
removal
.

Tightening
Torque

"
Fuel
rail
to
cylinder
head
..
.
..
..
...
10
Nm
(89
in-lb)

FUEL
INJECTION



130-
1
3

Fuel
Pressure
Regulator

The
fuel
pressure
regulator
location
on
E36
models
is

mounted
in
one
of
two
locations
:

Fuel
Pressure
Regulator
Location

"
4-cylinder
engines

1992-
January
1997
............
...
..
on
fuel
rail

January
1997-
on
...............
..
...
under
car

"
6-cylinderengines

1992-1995
.
.
...
...
.
...........
...
..
on
fuel
rail

1996-on
..
.
..
................
...
...
undercar

Fuel
pressure
regulator,
replacing

(fuel
rail
mount)

WARNING
-

Fuel
will
be
discharged
.
Do
not
disconnect
any
wires
that
could
cause
electrícal
sparks
.
Do
not
smoke
or
work
near
heaters
or
other
fire
hazards
.
Keepan
approved
fire
extinguisher
handy
.

9
.
On
6-cylinder
engines,
remove
top
engine
covers
.
Re-
move
fuel
rail
mounting
bolts
and
lift
up
fuel
rail
.

1
.
Disconnect
vacuum
hose
from
fuel
pressure
regulator
.

See
Fig
.
19
.

"
Fit
new
O-rings
when
installing
injectors
.
For
ease
of

installation,
lightly
lubricate
O-rings
with
SAE
90
or



0012732

equivalent
lubricant
.



Fig
.
19
.
Fuel
pressure
regulator
(arrow)
on
M42
engine
.
Vacuum
hose

"
Check
that
injector
electrical
connections
are
correctly



shown
at
A
.

fitted
and
that
injectors
are
fully
seated
prior
to
install-

ing
fuel
rail
mounting
bolts
.



2
.
Remove
bolt
from
regulator
clamp
.
Remove
clamp
.
Note

"
Replace
wire
ties
.



installed
direction
of
regulator
to
fuel
rail
.

3
.
Wrap
a
shop
rag
around
regulator,
then
remove
regula-

tor
from
fuel
rail
by
pulling
straight
out
.

FUELDELIVERYTESTS

u0
I
.[
Ia

Fig
.
21
.
Air
flow
sensor
harness
connector
terminal
identification
.

4
.
Replacing
air
flow
sensor
:

"
Remove
large
band
clamp
attaching
air
boot
to
sensor
.

"
Remove
airfiltertop
cover,
then
remove
airflow
sensor

mounting
nuts
inside
cover
.

"
Reconnect
air
boot
and
harness
connector
.

Engine
coolant
temperature
(ECT)
sensor,

testing
and
replacing

The
engine
coolant
temperature
(ECT)
sensor
sends
con-

tinuous
engine
coolant
temperature
information
to
the
ECM
.

As
temperature
increases,
sensor
resistance
decreases
.

"
With
harness
connector
disconnected,
check
resis-

tance
across
sensor
terminals
.

"
Compare
tests
results
to
values
in
Table
d
.

FUEL
INJECTION



130-
1
5

0011984

Fig
.
22
.
M42
engine
coolant
temperature
(ECG
sensor
(arrow)
.

Table
d
.
Engine
Coolant
Temperature
Sensoror

Intake
Air
TemperatureSensor
Test
Values

(DME
1
.7)

Test
temperatures



Resistance
(k
ohms)
',

14±2°F(-10t1°C)



7-11
.6

68±2°F
(20
t
1
°C)



2
.1
-2
.9

176
±
2°F
(80
t
V
C)



0
.27-0
.40

The
ECT
sensor
is
located
under
number
one
intake
run-



'

ner
.
See
Fig
.
22
.
NOTE-

1
.
Check
ECM
referente
voltage
to
sensor
:



The
test
values
listed
represent
only
three
test
points
from
a
continuous
resistance
NTC
sensor
.
Check
the
"
Disconnect
harness
connectorfrom
ECT
sensor
.



full
linear
response
to
increasing
temperature
as
the
"
Turn
ignition
key
on
.



engine
warms
up
.
"
Check
for
5
volts
between
supply
voltage
(brown/red)

wire
of
harness
connector
and
ground
.



3
.
If
ECT
sensor
fails
these
tests,
it
is
faulty
and
should
be

"
Turn
ignition
key
off
.



replaced
.
If
no
faults
are
found,
reconnect
electrical
"
If
voltage
is
not
present
or
incorrect,
check
wring
from



harness
.

ECM
and
check
ECT
sensor
reference
voltage
output

at
ECM
.
See
Table
h
.
NOTE-

2
.
Check
ECT
sensor
resistance
:



Use
a
new
copper
sealing
washer
when
installing
sen-
sor
.
Reptace
any
lost
coolant
.

WARNING
-

Do
not
replace
the
ECT
sensor
unlessthe
engine
is

cold
.
Hot
coolant
can
scald
.

Tightening
Torque

"
ECT
sensor
to
cylinder
head
.....
..
13
Nm
(10
ft-Ib)

BOSCH
DME
M1
.7
COMPONENT
TESTS
AND
REPAIRS