Wheel nut BMW 318i 1997 E36 User Guide

117-
8



CAMSHAFT
TIMING
CHAIN

Fig
.
18
.
Oil
baffle'
cover
being
removed
.

Fig
.
19
.
Upper
timing
chaincover
mounting
nuts
(arrows)
on
pre-
VANOS
engines
.

16
.
Secure
crankshaft
hub
to
prevent
crankshaft
from
turn-
ing
.
Using
a
socket,
loosen
but
do
not
remove
crank-
shaft
hub
center
bolt
.

CAMSHAFT
TIMINGCHAINS,
6-CYLINDER

Fig
.
20
.
Engine
set
to
approximate
TDC
.
Camshaft
lobes
face
in
and
arrows
on
sprockets
point
up
(arrows)
.

B1
1123a

Fig
.
21
.
O/
T
(0°TDC)
mark
on
vibration
damper
aligned
with
boss
on
timing
chain
cover
(arrow)
.

17
.
Lock
crankshaft
in
TDC
position
by
inserting
BMW
spe-

cial
tool
no
.
11
2
300
through
transmissionbellhousing
and
into
hole
in
flywheelor
drive
plate
.
See
Fig
.
23
.

NOTE-

Confirm
that
the
locking
tool
has
been
correctly
in-
stalled
by
trying
to
rotate
the
crankshaft
.
NOTE-

The
crankshaft
hub
center
bolt
is
tightened
to
a
torque



18
.
Remove
crankshaft
hub
bolt
and
washer
.
Remove
hub
of
410
Nm
(300
ft-ib)
.
A
heavy
duty
holding
device,



from
crankshaft
.
suchas
BMW
special
tool
no
.
112150,
should
be
used
to
hold
the
crankshaft
hub
stationary
while
the
bolt
is



19
.
Remove
cylinder
head
cover
mounting
studs
at
rear
of
loosened
.
Use
a
heavy
duty
314-inch
drive
socket
and



head
.
Lock
camshafts
at
TDC
using
BMW
special
tool
breaker
bar
to
break
the
bolt
free
.



no
.
11
3
240
at
ends
of
camshafts
.
See
Fig
.
24
.
.

117-
1
4



CAMSHAFT
TIMING
CHAIN

22
.
Installation
of
remaining
parts
is
reverse
of
removal,



When
theengine
is
running,
the
piston
housing
is
supplied

noting
the
following
:



with
pressurized
engine
oil
.
At
idie,
the
solenoid
isin
the
off

"
When
installing
thermostat,
make
sure
arrow
or
vent



position
(de-energized)
and
valve
timing
is
maintained
in
the

hole
faces
up,
if
applicable
.



normal
position
:
When
the
solenoid
is
energized,
the
gear
cup

"
Refill
cooling
systemas
described
in
170
Radiator



piston
moves
forward
to
advance
the
camshaftby
a
maximum

and
Coming
System
.



of
12
.5
.

"
Install
oil
pan
as
described
in
119
Lubrication
Sys-

tem
.
"
Fill
engine
with
oil
and
install
a
new
oil
filter
as
de-

scribed
in
020
Maintenance
Program
.

"
Insta¡¡
ground
wires
at
cylinder
head
cover
mounting

studs
and
at
front
of
cylinder
head
and
thermostat

housing,
where
applicable
.



VANOS
system
operation,
testing

Tightening
Torques



There
are3
special
tools
required
to
check
VANOS
opera-

"
Coolant
drain
plugto
cylinder
block
.
.
25
Nm
(18
ft-Ib)



tion
;
an
electricaltest
lead
(BMW
special
tool
no
.
12
6
410),
an

"
Radiator
cooling
fan
to
coolant
pump
.
40
Nm
(30
ft-Ib)



air
line
fitting
(BMW
special
tool
no
.
11
3
450),
and
a
crank-

"
Radiator
drain
screw
to
radiator
...
.
2
.5
Nm
(22
in-Ib)



shaft
TDC
locking
tool
(BMW
special
tool
no
.
112
300)
.

"
Upper
timing
chaincover
to
cylinder
head



The
test
leal
is
used
to
power
the
solenoid,
simulating
the
M6
nut
...
.....
.............
..
.
10
Nm
(89
in-lb)



ground
signal
from
the
DME
control
unit
.
The
air
line
fitting
M8
bolt
.....
....
.
.
.............
22
Nm
(17
ft-Ib)



takes
the
place
of
the
oil
supply
line
fitting
to
simulate
oil
Ares-
"
VANOS
control
unit
to
cylinder
head



sure
.
The
locking
tool
positions
and
locks
the
crankshaft
at

M6
nut
.........
..
..
.
..........
10
Nm
(89
in-lb)



TDC,
cylinder
no
.
l.
M8
bolt
........
...
.............
22
Nm
(17
ft-Ib)

"
VANOS
oil
supply
pipe
to
VANOS
control
unit



1
.
Remove
alternator
cooling
air
duct
.

banjo
bolt
.......
..
..
.
..........
32
Nm
(24
ft-Ib)

VANOS
(VARIABLE
VALVE
TIMING)



3
.
Remove
top
plastic
enginecovers
.
Disconnect
ignition

coil
harness
connectors
fromcofs
.
Remove
ignition

1993
and
later
6-cylinder
engines
are
equipped
with
a
vari-



coils
.

able
valve
timing
system
called
VANOS
.
This
system
is
con-

trolled
by
the
engine
management
system
and
dynamically



4
.
Remove
cylinder
head
cover
mounting
bolts
and
re-

adjusts
intake
camshaft
timing
based
on
engine
load,
engine



move
cylinder
head
cover
.
Unclip
andremove
oil
baffle

speed
and
engine
temperature
.



cover
from
above
intake
camshaft
.
See
113
Cylinder

Head
Removal
and
installation
.

The
main
components
of
the
VANOS
system
are
the
control

unit
with
piston
housing
and
integral
spool
valve,
and
the
mod-

ified
intake
camshaft
.
See
Fig
.
35
.

VANOS
(VARIABLE
VA
LVE
TIMING)

Fig
.
35
.
VANOS
control
unit
with
modified
intake
camshaft
.

B11001

WARNING
-

Special
BMW
service
tools
are
required
to
check
and
repair
the
VANOS
System
.
Read
theproce-

dures
through
before
beginning
the
job
.

2
.
Disconnect
crankcase
ventilation
hose
fitting
from
cyl-

inder
head
cover
.

NOTE-

Note
the
arrangement
of
the
cylinder
head
cover
bolt
insulators
and
gaskets
during
removal
.

5
.
Set
engine
to
approximate
TDC
by
rotating
in
normal

operating
direction
until
camshaft
lobes
at
cylinder
no
.

1
are
facing
each
other
.
See
Fig
.
20
.

6
.
Set
engine
to
TDC
by
aligning
"0/T"
mark
(0°TDC)on

front
vibration
damper
withcast
boss
on
lower
timing
chain
cover
.
See
Fig
.
21
.

7
.
Lock
crankshaft
in
position
by
inserting
BMW
special

tool
no
.
11
2
300
through
transmission
bellhousing
and

into
hole
in
flywheelor
driveplate
.
See
Fig
.
36
.

NOTE-

Confirm
that
the
locking
tool
has
been
correctly
in-
stalled
by
trying
to
rotatethe
crankshaft
.

117-
1
6



CAMSHAFT
TIMING
CHAIN

15
.
Remove
crankshaft
locking
tool
.
Remove
special
test

equipment
.
Insta¡¡
oil
supply
line
using
new
seals
and

reconnect
solenoid
connector
.
Remainder
of
installa-

tion
is
reverse
of
removal
.

Tightening
Torque

"
Cylinder
head
cover
to
cylinder
head
.
10
Nm
(89
in-lb)

"
VANOS
oil
supply
line
to
VANOS

control
unit
(banjo
bolt)



..
.........
32
Nm
(24
ft-Ib)

"
VANOS
solenoidlo
VANOS

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

VANOS
control
unit,
removing

Special
BMW
service
tools
are
required
lo
remove
and
in-

stall
the
VANOS
control
unit
.
Read
the
procedure
through
be-

forestarting
the
job
.

1
.
Remove
radiator
cooling
fan
shroud
and
cooling
fan
.

See
170
Radiator
and
Cooling
System
.

CAUTION-

Radiator
fan
has
left
hand
threads
.

2
.
Remove
top
plastic
engine
covers
.
Disconnect
ignition

coil
harness
connectors
from
coils
.
Remove
ignition

coils
.
Remove
cylinder
head
cover
.
Unclip
andremove

oil
baffle
cover
from
above
intake
camshaft
.See
113

Cylinder
Head
Removal
and
Installation
.

NOTE-

Make
note
of
the
mounting
bolt
insulator
arrangement
during
removal
of
the
cylinder
head
cover
.

3
.
Set
engine
lo
TDC
by
rotating
engine
in
normal
operat-

ing
direction
until
camshaft
lobes
at
cylinder
no
.
1
are

facing
each
other
and
"0/T"
mark
(0°TDC)
on
vibration

damper
lines
up
with
cast
boss
on
lower
timing
chain
cover
.
See
Fig
.
38
.

4
.
Lock
crankshaft
at
TDC
by
inserting
BMW
special
tool

no
.
11
2
300
through
transmission
bellhousing
and
finto

flywheel
or
drive
plate
.
Refer
to
Fig
.
36
given
earlier
.

NOTE-

Confirm
that
the
locking
tool
has
been
correctly
in-
stalled
by
trying
to
rotatethe
crankshaft
.

5
.
Remove
three
cylinder
head
cover
mounting
studs
from
rear
of
head
.
Lockcamshafts
at
TDC
bymounting

BMW
special
tool
no
.
11
3
240
at
ends
of
camshafts
.

Check
that
tool
is
squarely
seated
on
cylinder
head
gasket
surface
.
If
necessary,
rotate
camshafts
slightly
using
a24
mm
wrench
.
Refer
to
Fig
.
24
given
earlier
.

VANOS
(VARIABLE
VALVE
TIMING)

Fig
.
38
.
Camshafts
positioned
at
TDC-Cyl
.
No
.
1
cam
lobes
face
in
Note
0/T
mark
(0°TDC)
on
vibration
damper
alígned
with
boss
on
front
cover
.

CA
UTION-

Thecamshafts
mustbe
locked
in
the
TDC
position
using
the
specialservice
tool
or
an
equivalent
be-
fore
removing
the
timing
chain
.
Thearrows
on
the
sprockets
should
not
be
used
to
accurately
set
the
engine
to
TDC
The
special
tool
holds
the
cam-
shafts
parallel
to
each
other
and
perpendicular
to
the
valve
cover
gasket
surface
.

6
.
Disconnect
harness
connector
and
oil
line
fitting
from
bottom
of
VANOS
control
unit
.

NOTE-

Wrap
the
VANOS
oilfine
fitting
with
a
shop
rag
to
ab-
sorb
leaking
oil
.

7
.
Remove
two
access
plugs
from
VANOS
control
unit
in
frontof
exhaustcamshaft
sprocket
.
Loosen
4exhaustcamshaft
sprocket
mounting
bolts
but
do
not
remove

(Torx
El
0
socket)
.

NOTE-

Removal
of
the
access
plugs
allows
the
lower
exhaust
camshaft
sprocket
mounting
bolts
to
be
accessed
.

8
.
Depress
secondary
timing
chain
tensioner
and
lock
it
in
down
position
by
inserting
a
stiff
wire
into
rear
of
ten-
sioner
.
See
Fig
.
27
.

9
.
Remove
VANOS
control
unít
mounting
nuts
and
boltat

front
of
cylinder
head
.

117-
1
8



CAMSHAFT
TIMING
CHAIN

CAUTION-

It
is
crítical
that
the
exhaustcamshaft
sprocket
be

turned
only
the
mínimum
amount
necessary
to

engage
the
gear
cup
.
If
this
procedure
is
done
ín-
correctly,
the
VANOS
system
may
not
function

throughout
íts
full
range
.

NOTE-

As
the
control
unit
isinstalled,
the
secondary
sprockets
will
rotate
in
the
counterclockwise
direction
.
It
may
be

necessary
to
guide
sprockets
counterclockwise
as
the

control
unit
is
installed
.

8
.
On
cars
built
from3/95
:
Use
a
spanner
tool
(See
Fig
.

39
.),
turn
exhaust
sprocket
counterclockwise
(as

víewed
from
front
of
engine)
only
enough
to
mesh

gear
cup
splines
with
camshaftgear
.
Slowly
push

VANOS
control
unit
towards
camshaft
until
it
is
fully

seated,guiding
chains
in
counterclockwise
direction
.

CA
UTION-

Ensure
that
the
first
available
tooth
engages
.

9
.
Install
and
tightencontrol
unit
nuts
and
bolt
.

10
.
Connect
harness
connector
to
VANOS
solenoid
.
Using

new
seals,
insta¡¡
oil
line
fitting
.

Tightening
Torques

"
VANOS
control
unitto
cylinder
head

M6
nut
.....
..
..
.
.
.............
10
Nm
(89
in-lb)

M8
bolt
.....
.
.
.
.
..
.............
22
Nm
(17
ft-Ib)

"
VANOS
oil
supply
line
to
control
unit
.
32
Nm
(24
ft-Ib)

11
.
Slowlyunlock
and
release
secondary
chain
tensioner
.

12
.
Preloadprimary
chain
by
tightening
BMW
special
tool

no
.
112
240
(dummy
chain
tensioner)
to
1
.3
Nm
(11
in-
lb)
.
Then
tighten
exhaust
camshaft
sprocket
mounting

bolts
alternately
in
two
stages
.

Tightening
Torque

"
Secondarytiming
chain
sprockets
to
camshafts

(Tora
boits)

Stage
1
..
...............
...
.
.
...
5
Nm
(44
in-lb)

Stage
2
..
...............
...
.
.
..
22
Nm
(17
ft-Ib)

VANOS
(VARIABLE
VALVE
TIMING)

13
.
Remove
flywheel
locking
tool
from
transmission
bell-

housing
.
Remove
camshaft
locking
tool
from
rear
of

cylinder
head
.

14
.
Turn
engine
over
by
hand
at
least
two
fui¡
crankshaft
ro-

tations
.
Reinstall
camshaft
locking
tool
and
flywheel

locking
toolto
make
sure
all
adjustments
are
correct
.
If

settings
are
correct,
remove
locking
tools
.

15
.
Remove
BMW
special
tool
112
420
(dummy
chain
ten-
sioner)
from
side
of
cylinder
head
.
Install
primary
chain

tensioner
so
that
cutout
in
tensioner
piston
engages

chain
rail
.
See
Fig
.
34
.
Using
new
seals,
install
and

tighten
access
plugs
in
VANOS
control
unit
.

Tightening
Torque

"
Access
plugs
to

VANOS
control
unit
.
..
.
.....
.
..
...
50
Nm
(37
ft-lb)

"
Primary
timing
chain
tensioner
plug
to
tensioner
sleeve

M50/S50USengine
.
.
..
.
.
...
.
...
..
50
Nm
(37
ft-Ib)

M52/S52US
engine
...
..
...
...
...
40
Nm
(30
ft-Ib)

16
.
Install
oil
baffle
cover
above
intake
camshaft
.
Install

three
cylinder
head
covermounting
studs
to
rear
of

head
.
Instali
cylinder
head
cover
.

Tightening
Torque

"
Cylinder
head
cover

to
cylinder
head
(M6
screws)
......



10
Nm
(89
in-Ib)

17
.
Installationof
remaining
parts
is
reverse
of
removal
.

NOTE-

Be
sure
to
install
the
ground
wíres
at
the
cylinder
head
cover
mounting
studs
and
at
the
front
of
the
cylinder
head,
if
applicable
.

NOTE
-

The
guide
tube
is
sealed
in
the
pan
with
an
O-ring
.
Check
that
theO-ring
comes
out
with
the
tube
.
Use
a
new
O-ring
when
installing
the
tube
.

Fig
.
2
.



Oil
dipstick
guide
tube
mounting
nut
(arrow)
on
M44
engine
.
Use
new
O-ring
at
base
of
tube
during
installatidn
.

6
.
Install
engine
lifting
equipment
at
front
engine
lifting
point
and
raise
engine
approximately
5
mm
(
1
/4
inch)
until
engineweight
is
supported
.

7
.
Workingbeneath
car,
separate
steering
column
shaft
from
steeringrack
at
universal
joint
.

"
Point
wheels
straight
ahead
before
disconnecting
shaft

from
rack
.
Mark
steering
column
shaft
joint
to
steering

rackspíndle
.
See
320
Steering
and
Wheel
Align-

ment
.

CAUTION
-

In
order
to
avoíd
the
need
for
front-end
realign-
ment,
do
notunbolt
power
steering
rack
from
sus-
pension
crossmember
.

8
.
Supportsuspension
crossmember
(subframe)
from
be-
low
usingappropriate
jacking
equipment
.

9
.
At
left
and
right
sides,
unbolt
control
arm
bushing
carri-
ers
from
body
.
Disconnect
stabilizer
bar
links
fromcon-

trol
arms
.
See
Fig
.
3
.

LUBRICATION
SYSTEM



119-
3

0011960
Fig
.
3
.



Stabilizer
bar
link
nut
(A)
and
control
arm
bushing
carrier
bolts
(B)
.
Right
side
shows
.

10
.
Remove
bolts
from
left
and
right
sides
of
suspension
crossmember
.
RemoveM10
nuts
from
bottom
of
left
and
right
engine
mounts
.
Lower
crossmember
as
far
as

possible
.
See
Fig
.
4
.

uu1ibb4

Fig
.
4
.



Suspension
crossmember
bolts
(A)
and
lower
engine
mount-
ing
nut
(B)
.
Right
side
shows
.

11
.
Remove
clamping
brackets
holding
fuel
lines
to
oil
pan
.

12
.
On
cars
with
automatic
transmission,
remove
ATF
cool-
er
line
brackets
from
oil
pan
.

13
.
Remove
engine
drive
belt
from
power
steering
pump
.

See020
Maintenance
Program
.

14
.
Unbolt
power
steering
pumpbracket
andremove

bracket
with
pump
.
Hang
pump
from
chassis
using
wire
.

OIL
PAN

119-
4



LUBRICATION
SYSTEM

15
.
Remove
oil
pan
screws
.
Lower
andremove
oil
pan
to-

ward
rear
.



Tightening
Torques

"
Control
arm
bushing
carrier

CAUTION-



to
body(M10
bolt)
...............
42
Nm
(31
ft-Ib)

'



lf
the
oil
pan
does
not
separate
easily
from
the
en-



"
Engine
mount
to

gine
cylinder
block,
make
sure
all
mounting
bolis



suspension
crossmember
(M10
nut)
.
42
Nm
(31
ft-Ib)

have
been
removed
.
If
necessary,
a
few
tapswith



"
Front
suspension
crossmember
a
rubber
mallet
shouldbreak
it
free
.
Never
pry
the



to
body
.
.
..
...
..
.
....
See
310
Front
SusPension
oil
pan
loose
.
"
Oil
pan
to
engine
block
(M6
bolt)

8
.8
grade
..
....
.
...
...
.
........
10
Nm
(89
in-lb)
16
.
Installation
is
reverse
of
removal
.



10
.9
grade
...
..
.
....
..
.
.
.
.......
12
Nm
(9
ft-Ib)

"
Thoroughly
clean
all
old
gasket
material
from
mating



"
Power
steering
pump
to
bracket

surfaces
anduse
a
new
gasket
.



(self-locking
nuts)
....
..
.
....
..
.
..
22
Nm
(16
ft-Ib)

"
Applya
small
amount
of
non-hardening
sealer
(3-



"
Power
steering
pump
bracket
to
engine

Bond
O
l209
or
equivalent)
to
oil
pan
gasket
directly



block
or
oil
pan
(self-locking
nuts)
..
.
22
Nm
(16
ft-Ib)

below
joints
for
end
cover
and
front
timing
case
cover
.



"
Stabilizer
bar
link
to
control
arm
See
Fig
.
5
.



M8
nut
.................
...
.
...
22
Nm
(17
ft-Ib)
"
When
installing
oil
pan
to
engine,
tighten
forward



M10
nut
.....................
..
42
Nm
(31
Ib-ft)
screws
first,
then
tightenrear
.



"
Steering
column
universal
joint
"
Fill
engine
with
oil
as
described
in
020
Maintenance



to
steering
rack
spindle
(M8
bolt)
....
19
Nm
(14
ft-ib)
Program
.

0011950

Fig
.
5
.



Joint-mating
areas
at
oil
pan
gasket
where
sealer
should
be
applied
(arrows)
.
Apply
a
bead
3
mm
wideby
2
mm
high
.

OIL
PAN

WARNING
-

Always
use
new
bolis
when
mounting
the
subframe
to
the
body
.
The
one-timeonly
bolis
shouldbe
re-
placed
any
timethey
are
removed
.

NOTE-

The
oil
pickup
is
attached
to
the
oil
pan
using
self-tap-
ping
screws
.
For
this
reasonno
threading
for
the
pickup
is
present
on
new
oil
pans
.
Replace
the
seal
for
the
pickup
and
use
the
oíd
screws
to
rea
ttach
the
pickup
to
the
pan
.

Oil
pan,
removing
and
installing

(6-cylinder
engine,
1992models)

NOTE-

Cars
built
up
to
9/92
(1992models)usea
different
sus-
pension
crossmember
than
later
production
cars
.
Oil
pan
removalprocedureon
the
earlier
cars
requires
that
the
engine
be
raised
and
supportedfrom
above
.

1
.
Raise
car
and
place
securely
on
jackstands
.

2
.
Remove
splash
shield(s)
from
under
engine,
where
ap-

plicable
.

3
.
Drain
engine
oil
as
described
in
020
Maintenance
Pro-

gram
.

4
.
Remove
complete
exhaust
system
.
See180
Exhaust

System
.

5
.
Remove
air
filter
housing
complete
with
mass
air
flow

sensor
.
See
113
Cylinder
Head
Removal
and
Instal-

lation
.

6
.
Remove
alternator
cooling
duct
from
alternator
and
ra-
diator
support
.

7
.
Remove
radiator
cooling
fan
and
fan
shroud
.
Remove

radiator
securing
clips
at
top
of
radiator
.
See
170
Radi-

ator
and
Cooling
System
.

Center
the
steering
spindle
to
the
steering
rack
before
in-



NOTE-

stalling
the
steering
column
shaft
.
See
320
Steering
and



The
radiator
cooling
fan
nut(32
mm
wrench)
has
left

Wheel
Alignment
for
specific
installation
markings
and
pro-



hand
threads
.

cedures
.

5
.
Remove
air
filter
housingcomplete
with
mass
air
flow
sensor
.
See113
Cylinder
HeadRemoval
and
Instal-
lation
.

6
.
Remove
oil
dipstick
guide
tube
mounting
bolt
.
Discon-
nect
oil
separator
hose
frombase
of
guide
tube
and
re-
move
tubefrom
oil
pan
(where
applicable)
.
See
Fig
.
10
.

NOTE-

The
guide
tube
is
sealed
in
the
blockusing
an
O-ring
.
Check
that
the
O-ring
comes
out
with
the
tube
.
Use
a
new
O-ring
when
installing
the
tube
.

Fig
.
10
.
Oil
dipstick
guide
tube
being
removed
.
Use
new
O-ring
(ar-
row)
during
installation
.

7
.
M50/S50US
engine
:
Using
a
clean
syringe,
remove
power
steering
fluid
from
fluid
reservoir
.
Disconnect
power
steering
fluid
lines
from
steering
rack
.
See
320
Steering
and
Wheel
Alignment
.

8
.
M52/S52US
engine
:
Unbolt
power
steering
reservoir
from
engíne,
then
tie
to
chassis
with
wire
.

9
.
Insta¡¡
engine
lifting
equipment
atfront
engine
lifting
point
and
raise
engine
approximately
5
mm
('/a
inch)
until
engineweight
is
supported
.
See
Fig
.
11
.

10
.
Workingbeneath
car,
separate
steering
column
shaft
from
steeringrack
at
universal
joint
.

"
Mark
steering
column
shaft
jointto
steering
rack
spin-

dle
.
Point
wheels
straight
ahead
before
disconnecting
shaft
from
rack
.
See
320
Steering
and
Wheel
Align-
ment
.

LUBRICATION
SYSTEM



119

Fig
.
11
.
Engine
lifting
equipment
shown
installed
acrossengíne
.

CA
UTION-

In
order
to
avoid
the
need
for
front-end
realign-
ment,
donot
unbolt
power
steering
rack
from
sus-
pension
crossmember
.

11
.
Support
suspension
crossmember
from
below
using
appropriate
jacking
equipment
.

12
.
Loosen
nuts
at
top
of
left
and
right
side
engine
mounts
.
Remove
nuts
from
bottom
of
left
and
right
side
engine
mounts
.

13
.
At
left
and
right
sides,
unbolt
control
arm
bushíng
carri-
ers
from
body
.
Disconnect
stabilizer
bar
links
fromcon-
trol
arms
.
Refer
to
Fig
.
3
.

14
.
Remove
bolts
from
left
and
right
sides
of
suspension
crossmember
and
lower
front
axle
as
far
as
possible
.

15
.
Remove
fuelline
clamping
brackets
from
oil
pan
.
On
cars
with
automatic
transmission,
remove
ATF
cooler
line
brackets
from
oil
pan
.

16
.
Remove
oil
pan
screws
.
Lower
and
remove
oil
pan
for-
ward
to
remove
.

CA
UTION-

If
the
oil
pan
does
not
separate
easily
from
the
en-
gine
cylinder
block,
a
few
taps
with
a
rubber
mallet
shouldbreak
it
free
.
Do
notpry
the
oil
pan
loose
.

OIL
PAN

119-
8



LUBRICATION
SYSTEM

17
.
Installation
is
reverse
of
removal
.

"
Thoroughly
clean
all
old
gasket
material
from
mating

surtaces
anduse
a
new
gasket
.

"
Applya
small
amount
of
non-hardening
sealer
(3-Bond

1209
0
or
equivalent)
to
oil
pan
gasket
directly
below

joints
for
and
cover
and
front
timing
case
cover
.
See

Fig
.
12
.

"
Tighten
oil
pan
bolts
starting
at
front
first,
working
to-

wardback
(transmission)
end
.

"
Fill
engine
with
oil
as
described
in
020
Maintenance

Program
.

"
After
addingengine
oil,
start
and
run
engine
.
Raiseen-

gine
speed
to
2,500
rpm
until
oíl
pressure
warning

lampgoes
out
(about
5seconds)
.

OIL
PUMP

applied
(arrows)
.
Apply
a
bead
3
mm
wideby
2
mm
high
.

WARNING
-

"
Always
use
new
bolts
when
mounting
the
sub-

frame
to
the
body
.
The
one-time
only
bolts
should
be
replaced
any
timethey
are
removed
.

"
Special
installation
instructions
apply
when
in-
stalling
the
front
suspension
crossmember
to
the
body
.
See
310
Front
Suspension
for
fastener
specifications
and
tightening
torques
.

Fig
.
12
.
Joint-mating
areas
at
oil
pan
gasket
where
sealer
should
be

Center
the
steering
spindle
to
the
steering
rack
before
in-

stalling
the
steering
column
shaft
.
See
320
Steering
and

Wheel
Alignment
for
more
specific
procedures
.

Tightening
Torques

"
Control
arm
bushing
carrier

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

"
Engine
mount
to

suspension
crossmember(M10
nut)
..
42
Nm
(31
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)

"
Stabilizer
bar
link

to
control
arm
(M10
nut)
.......
....
42
Nm
(31
Ib-ft)

"
Steering
column
universal
joint

to
steering
rack
spindle
(M8
bolt)
....
19
Nm
(14
ft-Ib)

"
Suspensíon
crossmember

to
body
...
...
.
...
..
.
.
See
310
Front
Suspension

OIL
PUMP

Oil
pump,
removing
and
installing

(4-cylinder
engine)

Oil
pressure
on
M42
and
M44
engines
is
generatedbya

gear-type
pump
mounted
to
the
rear
of
the
front
engine
cover

(timing
chaincase)
.
The
pump
is
gear-driven
off
the
front
of

the
crankshaft
.

NOTE-

Oil
pump
removal
requires
lowering
of
the
front
sus-

pension
and
removal
of
the
oil
pan,
as
well
asremoval
of
the
timing
chain
assembly
.

1
.
Disconnect
negative
(-)
battery
cable
from
battery
.

CAUTION-

Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
paga
vÍii
.

2
.
Drain
engine
oil
as
described
in
020
Maintenance
Pro-

gram
.

3
.
Withengine
cold,
drain
coolant
.
See
170
Radiator
and

Cooling
System
.

4
.
Remove
top
cover
from
oil
filter
housing
to
allow
engine

oil
to
drain
into
oil
pan
.
Remove
oil
pan
as
described

earlier
.
Reinstall
oil
filter
cover
.

5
.
Remove
alternator
.
Unbolt
power
steering
pump
from

bracket,
then
remove
alternator
mountíng
bracket
.
See

121
Battery,
Starter,
Alternator
.

6
.
Remove
crankshaft
vibration
damper
andhub
.
Then
re-

move
upper
and
lower
timing
chain
covers,
complete

timingchain,
chain
sprockets
and
chain
guides
.
See

117
Camshaft
Tíming
Chain
.

121-
8



BATTERY,
STARTER,
ALTERNATOR

1f
the
solenoid
audibly
cliicks
but
the
motor
does
not
turn,



Starter,
removing
and
installing
switch
on
the
lights
andtum
the
key
to
the
start
position
.
lf
the



(6-cylinder
engine
with
lights
go
out
while
attempting
to
start,
the
battery
cable
may
be



manual
transmission)
loose
or
the
starter
may
have
a
short
circuit
.
If
the
lights
stay

on,the
solenoid
is
most
likely
atfault
.
The
starter
on
a
6-cylinder
car
with
manual
transmission
is

Starter,
removing
and
installing

(4-cylinder
engine)



1
.
Disconnect
negative
(-)
battery
cable
.

1
.
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
.

2
.
Remove
guide
tube
for
oil
dipstick
.

3
.
Raise
vehicle
.

WARNING
-

Make
sure
the
car
ís
stable
and
wefl
supported
at
all
times
.
Use
a
professional
automotive
lift
or
jack
stands
designed
forthe
purpose
.
A
floor
jack
is
not
adequate
support
.

4
.
Disconnect
wiring
from
starter
.

5
.
Remove
top
and
bottom
starter
bolts
.
Bottom
bolt
must

be
removed
from
below
car
.
Remove
starter
support

bracket,
if
applicable
.

removed
from
below
.

2
.
Raise
vehicle
.

3
.
Remove
reinforcing
cross
bracefromunder
transmís-

sion,
if
applicable
.

4
.
Remove
cover
from
fuel
filter
and
fuel
lines
on
left
side

underneath
car,
if
applicable
.
Detach
fuel
lines
and
har-

ness
connectors
from
retainingbrackets,
as
necessary

5
.
Disconnect
wiring
from
starter
.

6
.
Loosen
andremove
bolts
and
nuts
fastening
starter
to

transmission
bell
housing
and/or
engine
block
.
Remove

starter
supportbracket
.

7
.
Remove
starter
from
below
.

8
.
Check
starter
pinion
gear
and
flywheel
teeth
for
dam-

age
.

9
.
Installation
is
reverse
of
removal
.

6
.
Pull
starter
downward
and
turn
until
solenoid
is
at
top,



Tightening
Torques

then
remove
from
car
.



"
Re¡
nforcing
cross
brace

to
chassis
(M10)
..
...............
42
Nm
(31
ft-Ib)

7
.
>Check
starter
pinion
gear
and
flywheel
teeth
for
dam-



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

age
.



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

"
Support
bracket

8
.
Installation
is
reverse
of
removal
.



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

"
Wire
to
terminal
50
(M6
nut)
.........
6
Nm
(53
ín-Ib)

"
Wire
to
terminal
30
(M8
nut)
.........
12
Nm
(9
ft-lb)

Tightening
Torques

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

Wire
to
terminal
50
(M6
nut)
........
6
Nm
(53
in-lb)

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

STARTER
SERVICE

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
.