Automatic BMW 325i 1993 E36 User Guide

020-
8



MAINTENANCE
PROGRAM

FLUID
AND
LUBRICANT
SPECIFICATIONS
The
fluids
and
lubricante
specified
by
BMW
are
listed
in
Ta-

ble
e
.
Shown
below
is
engine
oil
viscosity
(SAE
grade)
vs
.
oper-

ating
temperature
range
for
the
BMW
enginescovered
in
this

manual
.

Engine
Oil
Viscosity
Requirements

vs
.
Temperature

`S
EAVic
P
Q
SAE
swao

YCO

0

N

M42
engine



1
.1
I
(1
.2
US
qt
.)
M44
engine



1
.1
l(1.2
US
qt
.)
M50
engine



1
.1
1(1.2
US
qt
.)
M52
engine



1
.21(1.3
US
qt
.)
S50US
engine



1
.21(1.3
US
qt
.)
S52US
engine



1
.21(1.3
US
qt
.)

°F
80

-

1o-0
-
30
-----20

WARNING
-

The
use
of
fluids
that
do
not
meet
BMWs
specifica-
tions
may
impair
performance
and
refability,
and
may
void
warranty
coverage
.

Tablee
.
Fluids
and
Lubricants

0013227

Fluid
Approximate
Specification
capacity

Engine
oil
with
filter
change

M42
engine



5
.01
(5
.3
US
qt
.)
M44
engine



5
.0
I
(5
.3
US
qt
.)
M50
engine



6
.5
I
(6.9
US
qt
.)



API
service
SH
or
M52
engine



6
.51
(6.9
US
qt
.)



si
S50US
engine



6
.51
(6.9
US
qt
.)
S52US
engine



6.0
I
(6.3
US
qt
.)

Manual
transmission
oil

FLUID
AND
LUBRICANT
SPECIFICATIONS

See
230Manual
Transmission
for



NOTE-
fluid
specification

Tablee
.
Fluids
and
Lubricants
(continued)

Fluid
Approximate
Specification
capacity

Automatic
transmission
fluid
(ATF)
(drain
and
fill)
(additional
fluid
required
when
installing
a
drytorque
converter)

A4S
310R



See240
AutomaticTransmission
for
fluid
A4S
270R



specification
information
A5S
310Z

Final
drive
(drain
and
fill)
(Lifetime
fluid
;
no
fluid
change
required)

4-cylinder



1
.1
I
(1.2
US
qt
.)



BMW
SAF-XO
6-cylinder



1.7
l(1
.8
US
qt
.)



synthetic



oil



(ex
.
limited
slip)
BMW
SAF-X1-S
synthetic
oil
(limit-
ed
slip)

Power
steering
fluid

Al¡
modeis



permanentlysealed



Dexron
IIPATFno
drain
plug

rake
fluid

All
modeis



-
~
S
AE
Dot4

Engine
coolant

M42
engine



6
.51(6
.9
US
qt
.)
M44
engine



6
.51(6
.9
US
qt
.)
M50
engine



10
.51
(11
.1
US
qt
.)



50%
BMW
anti-
M52
engine



10
.5
1
(11
.1
US
qt
.)



freezel
50%
water
S50US
engine



10
.75
1(11
.4
qt
.)
S52US
engine



10
.75
I
(11
.4
qt
.)

CA
UTION-

Multi-viscosity
engine
oils
should
not
beused
in
the
manual
transmission
.
Use
of
such
an
oil
could
shorten
the
service
life
of
thetransmission
.

Manual
Transmission
Fluid

The
manual
transmissions
installed
in
the
E36
modeis
are

normallyfilled
with
automatic
transmission
fluid
(ATF),
although

alternative
synthetic
lubricants
may
havebeen
used
from
-
the

factory,
depending
on
transmission
type
and
model
year
.
Con-

sult
230
Manual
Transmission
for
additional
information
on

identifying
the
type
of
fluid
installed
.

Automatic
Transmission
Fluid

The
automatic
transmissions
installed
in
the
E36
modeis
are
normally
filled
with
Dexron
111
automatic
transmission
fluid

(ATF),
although
alternative
fluids
havebeen
installed
from
the

factory,
depending
on
transmission
type
and
model
year
.
Some
transmission
are
filled
with
a
special
BMW
"life-time"
automatic
transmission
fluid,
whích
does
not
requireperiodic
fluid
changes
.
Consult
240
Automatic
Transmission
for
ad-
ditional
fluid
specification
information
.

information



1



The



11-



11
lubrican
type
canbefound
on
ti
¡e
`Yype
plate"
on
the
side
of
the
transmission
.
Consult
an
authorized
BMW
dealer
foralternate
fluid
use
and
the
Continued



most-up-to-date
information
regarding
transmission
op-
erating
fluids
.

Accelerator
and
Throttle
Linkage

The
accelerator
and
throttie
linkage
should
be
lubricated
pe-
riodically
.
Use
a
general
purpose
oil
on
the
joints
and
bearings

of
the
linkage
.
Use
a
multipurpose
grease
on
the
bearing
points

of
the
throttie
plate
.

Engine
Drive
Belts

Drive
belts
and
pulleys
transfer
power
from
theengine
crank-

shaft
to
various
accessories
.
See
Fig
.
13
.
Depending
on
model

and
model
year,
engine
driven
accessories
are
driven
by
V-

belts,
poly-ribbed
(serpentine)
belts,
or
a
combination
of
the

two
.
For
example,
early
4-cylinder
engines,
usetwo
V-belts
and
one
poly-ribbed
belt
.

Inspect
drivebelts
with
the
engine
off
.
lf
the
belt
shows
signs

of
wear,
cracking,
glazing,
or
missing
sections,
it
should
be
re-

placed
immediately
.

V
belt,
replacing

(4-cylinder
engines
built
up
to
1194)

0012472

Fig
.
13
.
Drive
belt
and
tensioner
assembly
for
late
4-cylinder
engine
wíth
poly-ribbed
drive
belt
.

V-belts
should
be
inspected
during
regular
maintenance
in-

tervais
.
Incorrect
tension
can
decrease
the
life
of
the
belt
and

the
component
it
drives
.
The
V-belt
tension
is
adjusted
through

a
toothed-rack
mechanism
.

Inspect
belts
with
the
engine
off
.
Twist
the
beltto
inspect
its

sidewalls
and
bottom
.
Beltstructural
damage,
glazed
or
shiny

sidewaljs
caused
by
a
loose
belt,
orseparation
are
al¡
reasons

to
replace
a
belt
.

Replacement
of
the
V-belts
every
four
years
is
recommend-

ed
.
Loosen
the
mounting
bolts
and
adjust
the
belt-driven
unit

until
the
belt
tension
is
as
loose
aspossible
.
Remove
the
belt
by

slipping
it
over
the
pulleys
.
In
some
cases
it
may
be
necessary

to
removeone
V-belt
to
get
to
another
.
Use
a
torque
wrench
and

a
crowfoot
wrench
to
turn
the
tensioning
gear
bolt
and
set
belt

tension
.
Hold
the
wrench
steady
and
tighten
the
locknut
on
the

rear
of
the
tensioning
gear
bolt
.
Tighten
al¡
other
mounting
nuts
.

MAINTENANCE
PROGRAM



020-
1
3

NOTE-

"
For
the
most
accurate
check,
V-belt
tension
should
be
checked
using
a
V-belt
tension
gauge
.

"
Belt
squealing
is
normally
caused
by
loose
beltten-sion
.
Belt
dressings
should
not
be
used
.

Tightening
Torques

"
Tensioning
gear
(alternator

belt
tensioning)
.
.
.
...............
7
Nm
(62
in-lb)

"
Tensioning
gear(power
steering

belt
tensioning)
...
..
...
8
to
8
.5
Nm
(71
to
75
in-lb)

"
Tensioning
gear
locking
nut
.......
24
Nm
(18
ft-Ib)

NOTE-

When
belts
are
replaced
with
new
ones,
store
the
old
set
in
the
luggage
compartment
for
emergency
use
.

When
installing
a
new
belt,
gently
pry
it
over
the
pulleys
.
Too

much
force
may
damage
the
belt
or
the
accessory
.
Tension
the

belt(s),
runthe
engine
for
a
few
minutes
(at
least
1500
rpm),

then
recheck
the
belt
tension
.

CAUTION-

Do
not
over
tighten
the
V-belts
.
Overtightening
will
cause
shaft
bearings
to
fail
prematurely
.

Poly-ribbed
belt,
replacing

(4-cylinder
engines
buiit
from
1194

and
all
6-cylinder
engines)

An
automatic
belt
tensioner
is
used
to
keep
the
belts
ten-

sioned
properly
.
Unless
the
tensioner
mechanism
malfunc-

tions,
the
poly-ribbed
belts
do
not
require
tension
adjustment
.

To
reduce
the
chance
ofbelt
failure
while
driving,
replace-

ment
of
the
belts
every
four
years
is
recommended
.
Mark
drive

belt
rotationdirectíon
if
removing
and
reusing
an
old
belt
.

To
remove
the
belt,
it
is
necessary
toretract
the
self-tension-

er
.
Using
a
breaker
bar
or
other
long
socket
assembly,
rotate

the
tensioner
to
loosenthe
belt
.
See
Fig
.
14
or
Fig
.
15
.
On
4-cyl-

inder
engines,
it
will
benecessary
to
remove
the
A/C
compres-

sor
belt
to
remove
the
main
drive
belt
.

WARNING
-

Observe
care
when
replacing
the
belt
.
Personal
in-
jury
could
result
if
the
tensioner
springs
back
into
position
uncontrollably
.

With
the
belt
removed
from
the
pulleys,
inspect
the
pulleys

for
wear
or
damage
that
may
cause
early
failureof
the
new
belt
.

This
is
also
a
good
opportunity
to
inspect
the
belt-driven
acces-

sories,
checking
for
bearing
wear
and
excess
play
.
Drive
belt

routing
is
shown
in
Fig
.
16
and
Fig
.
17
.

ENGINE
COMPARTMENT
MAINTENANCE

020-
1
8



MAINTENANCE
PROGRAM

Fig
.
25
.
Inspect
brake
pads
with
the
caliper
removed
.
Minimum
brake
pad
thickness
shown
by
dimension
(A)
.

NOTE-

The
parking
brake
may
lose
some
of
its
effectiveness
if
it
is
not
used
frequently
.
This
is
due
to
corrosion
build-
up
on
the
parking
brake
drum
.
To
remove
corrosion,
ap-
plythe
parking
brake
just
until
it
begins
togrip,
then
pulí
the
lever
up
one
more
stop
(click)
.
Drive
thecar
approx-
imately
400
meters
(1,300
ft
.)
and
release
the
brake
.
To
recheck
the
adjustment
of
the
parking
brake
see340
Brakes
.

UNDER-CAR
MAINTENANCE

0011920

Manual
transmission
fluid,

checking
and
filling

The
manual
transmission
fluid
leve¡
should
be
checked
at

specified
intervals
.
Check
and
fill
the
transmission
with
the
car

ona
leve¡
surface
.
Transmission
(luid
leve¡
checking
and
re-

placement
procedures
are
covered
in
230
Manual
Transmis-

sion
.

Automatic
Transmission
Service

The
automatic
transmission
is
not
equipped
with
a
dipstíck
.

Therefore,
checking
the
ATF
level
is
an
ínvolved
procedure,

which
includes
measuring
and
maintaining
a
specified
ATF

temperature
during
the
checking
procedure
.

For
more
complete
ATF
service,
including
checking
ATF
lev-

e¡
and
ATF
filter
replacement
procedures,
see
240
Automatic
Transmission
.

Front
suspension
and
steering
linkages,

inspecting

Inspection
of
the
front
suspension'and
steering
includes
a
check
of
all
moving
parts
for
wear
and
excessive
play
.
Also
in-

spect
the
rubber
seals
and
boots
for
cracks
or
tears
that
could

allow
the
entry
of
dirt,
water,
and
other
contaminants
.
See
310

Front
Suspension
.

Exhaust
system,
inspecting



Rear
suspension,
inspecting
Exhaust
system
life
varies
widely
according
to
driving
habits



Final
drive
and
rear
drive
axle
service
consists
of
checking

and
environmental
conditions
.
If
short-distance
driving
pre-



and
changing
the
gear
oil,
inspecting
for
leaks,
and
checking
dominates,
the
moisture
and
condensation
in
the
system
will



the
rear
drive
axle
rubber
boots
for
damage
.
not
fully
dryout
.
This
will
lead
to
early
corrosion
damage
and
more
frequent
replacement
.
The
areas
where
leaks
are
most
likely
to
occur
are
around
the
driveshaft
and
drive
axle
mounting
flanges
.
For
more
infor

Scheduled
maintenance
of
the
exhaust
system
is
limitedlo



mation
on
ídentifying
oil
leaks
and
their
causes,
see330
Rear
inspection
.
Check
for
restrictions
due
to
dents
or
kinks
.
Check



Suspension
.
for
weakness
or
perforation
due
to
rust
.
Check
lo
see
that
all
the
hangers
are
in
place
and
properly
supporting
the
system
and
that
the
system
does
not
strike
the
body
.
Alignment
of
the
sys-



Final
drive
oil
leve¡,
checking

temand
the
location
of
the
hangers
aredescribed
in
180
Ex-
haust
System
.



Check
the
lubricant
leve¡
with
thecar
level
.
Remove
the
oil
filler
plug
.
The
leve¡
is
correct
when
the
fluidjust
reaches
the

edge
of
the
filler
hole
.
Install
and
tighten
the
oil
filler
plug
when
Manual
Transmission
Service



the
oil
level
is
correct
.
See
Fig
.
26
.

Manual
transmissionservice
consists
of
inspectingfor
leaks



The
final
drive
should
be
filled
with
a
special
BMW
lubricant
and
checking
and
changing
the
fluid
.



available
through
an
authorized
BMW
dealer
.
In
addition,
the
lubricant
type
varies
depending
onwhether
or
nota
limited-slip
Evidence
of
transmissionleaks
is
fkely
to
beseenaround
the



differential
is
fitted
.
driveshaft
mounting
flange
and
at
the
bottom
of
the
bellhousing
.
For
more
information
on
identifying
oil
leaks
and
their
causes,
see230ManualTransmissionand210
Clutch
.



Tightening
Torque

"
Finaldrive
filler
plug
to
final
drive
housing
..................
70
Nm
(52
ft-Ib)

Graphic
representation
of
flashing
Check
Engine
light
fault
code
:
1221

-
;
5
Seconds
.
~-



2
.5;-

Fault
code
and
meaning



Corrective
action

Code
1286
:
Knock
control
test
pulse
(DME
3
.3
.1
only)



Check
DME
control
module
inputs/outputs
.
Control
module
may
be
faulty
Repair
Group
130

Code
1000
(light
remains
off)
:



End
of
fault
code
output-all
fault
codes
have
been
displayed
.
No

~
corrective
action
necessary
.
Repeat
test
if
necessary

Code
1444
:



No
more
faults
.
No
corrective
action
necessary
.
This
code
must
be
present
lo
erase
fault
memory

Basic
Requirements



Preventive
Maintenance

The
following
list
contains
basic
checks
that
should
be
made
when
experiencing
driveability
problems
.

1
.
Check
intake
(induction)
system
for
leaks
.
Check
for

cracked,
loose,
or
disconnected
hoses
and
duct
work
.

Check
that
all
hose
clamps
are
tight
.

NOTE-

An
air
leak
allows
unmeasured
airto
enter
the
engine,
offen
resulting
in
an
in
overly
lean
fuel
mixture
and
causing
driveability
problems
which
will
cause
the
Check
Engine
light
to
come
on
.

Table
d
.
OBD
I
Fault
(Blink)
Codes
(continued)

(1992-1995
models
only)

7
-
1
--------------
Check
Engine
light
on

ENGINE-GENERAL
100-
1
1

Check
Engine
light
off

The
condition
of
the
fuel,
ignition
and
emission
controlsys-

tem
components
has
a
directeffect
onengineperformance

and
driveability
.
BMW
specifies
maintenance
of
certain
parts

at
regular
intervals
lo
keep
the
engine
in
proper
tune
.
Extend-
ing
maintenance
intervals
beyond
the
time
or
mileagerecom-
mended
bythe
manufacturer
can
adversely
affect
the
way
the
engine
runs
.
When
troubleshooting
driveability
problems,
a
good
starting
point
is
to
perform
a
major
engine
service,par-

ticularly
if
one
is
overdue
.
For
maintenance
schedules,
major
engine
service
and
other
driveability-related
maintenance

procedures,
see020
Maintenance
Program
.

Basic
Engine
Settings

2
.
Check
that
the
battery
isin
good
condition
.
Check
that

the
cables
are
tight
and
free
of
corrosion
at
both
ends
.



Idle
speed,
idle
mixture
(%CO),
and
ignition
timing
are
not

Check
that
all
related
ground
points
are
firmly
connect-



adjustable
.
The
adaptive
engine
management
system
is
de-

ed
and
in
good
condition
.
Check
al¡
harness
connectors



signed
lo
automatically
compensate
for
changes
in
engine
op-

for
damage
and
corrosion
.



erating
conditions,
although
the
adaptive
range
is
limited
.

Once
these
limits
are
exceeded,
driveability
problems
usually

3
.
Check
for
prwer
and
ground
at
the
Engine
Control



become
noticeable
.

Module
(ECM)
.
Check
the
main
grounds
for
the
ECM
.

See130
Fuel
Injection
.



NOTE-

If
the
DME
adaptive
limits
are
exceeded,
the
Check
En-
4
.
Check
the
fuses
.
Check
for
sufficient
fuel
in
the
tank
.
If



gine
light
will
come
on,
indicating
an
emission
related
the
engine
ranout
of
fuel,
it
will
take
a
little
time
to
re-



fault
.
See
130
Fuel
Injection,
store
fuel
pressure
.
See
160
Fuel
Tank
and
Fuel

Pump
.
Oxygen
Sensors

5
.
Check
for
spark
at
the
spark
plugs
.
If
the
tachometer

needle
bounces
while
the
engine
is
crankedby
the



A
high
oxygen
level
in
the
engine
exhaust
indicates
a
lean

starter
then
the
ignition
system
is
probably
working
cor-



air-fuel
mixture
and
a
low
oxygen
level
indicates
a
rich
mix

rectly
.
See
120
Ignition
System
.



ture
.
The
oxygen
sensor,
shown
in
Fig
.
10,
measures
the
oxy-

gen
content
in
the
exhaust
gasand
generates
a
variable

6
.
Check
for
any
faults
through
the
On-Board
Diagnostics



voltage
signal
.
Using
that
feedback
signal
asan
input,
the

system
.
See
On-Board
Diagnostics
(OBD)
.



DME
control
module
fine
tunes
the
air-fuel
mixture
.

DRIVEABILITY
TROUBLESHOOTING

110
Engine
Removal
and
Installation

GENERAL
.
.
.
.
.......
.
.
.
..........
.
...
110-1



Engine,
removing
and
installing
(4-cylinder
engines)
.
..
.....
..
...........
110-1

ENGINE
REMOVAL
AND
INSTALLATION
110-1



Engine,
removing
and
installing
(6-cylinder
engines)
..
...
...
..
.....
..
....
110-4

GENERAL

Some
special
tools
are
required
for
removal
and
installation
of
the
engine
.
Be
sure
to
have
the
necessary
equipment
on
hand
before
starting
thejob
.

CAUTION-

"
Engine
removal
requires
disconnecting
the
bat-
tery
.
This
may
erase
any
system
fault
code(s)
that
havebeen
stored
in
control
unit
memories
.
Check
forfault
codes
prior
to
disconnecting
the
battery
cables
.

"
If
the
Check
Engine
lightis
illuminated
with
the
engine
running,
see
100
Engine-General
for
On-Board
Diagnostics
(08D)
fault
code
infor-
mation
.
"
If
any
other
system
faults
have
been
detected,
as
indicated
by
an
illuminated
ANTI
LOCK,
SRS
or
AST
warning
light,
see
the
appropriate
repair
group
inthis
manual
or
an
authorized
BMW
dealer
for
more
information
on
fault
codes
.

ENGINE
REMOVALAND
INSTALLATION

Engine,
removing
and
installing

(4-cylinder
engines)

Cover
al¡
painted
surfaces
before
beginning
theremoval

procedure
.
Asan
aid
to
installation,
label
al¡
components,

wires,
and
hoses
before
removing
them
.
Do
not
reuse
gas-

kets,
O-rings
or
seals
during
reassembly
.

WARNING
-

Due
to
risk
of
personal
injury,
be
sure
the
engine
is

cold
before
beginning
the
removalprocedure
.

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

compartment
.



0011969

CAUTION-

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

ENGINE
REMOVAL
AND
INSTALLATION



110-1

2
.
Remove
transmission
from
car
.
See230
Manual
Transmission
or
240
Automatic
Transmission
.

3
.
Remove
enginehood
or
place
hood
in
service
positíon
.
See
410
Fenders,
Engine
Hood
.

NOTE-

tt
is
notnecessary
to
remove
the
engine
hood,
but
it
is
helpful
and
will
make
engine
removal
and
installation
easier
.

4
.
Remove
splash
guard
under
engine,
if
applicable
.

5
.
Unbolt
ignition
coil
assembly
from
bracket
on
strut
tow-er
.
Disconnect
wiring
to
ignition
cofs,
then
place
coil
assembly
on
engine
.

6
.
Disconnect
al¡
cables
and
harness
connectors
at
throt-
tle
housing
.

7
.
Unbolt
andremove
complete
air
cleaner
housing
with

mass
air
flow
sensor,
disconnecting
and
labeling
con-

nectors,
ducting
and
hoses
asnecessary
.
See
Fig
.
1
.

Fig
.
1
.



Intake
air
duct
hose
clamp
(A),
mass
air
flow
sensor
connec-
tor
(B),
and
air
cleanerto
air
flow
sensor
clips
(C)
on
M44
en-
gine
.

ENGINE
REMOVAL
AND
INSTALLATION

14
.
Unbolt
power
steering
fluid
reservoir
from
íts
mounting
bracket
.
Use
stiff
wire
to
hang
reservoir
to
one
side
.
Do
not
disconnect
fluid
lines
.

15
.
Remove
power
steering
pump
drive
belt
and
remove
pump
from
its
mounting
bracket
.
Use
stiff
wire
to
hang
pump
from
body
.

16
.
On
cars
with
automatic
transmission
remove
front
and
rear
brackets
holding
automatic
transmission
cooler
linesto
engine
.

17
.
Remove
A/C
compressor
from
its
mounting
bracket
without
disconnecting
any
refrigerantlines
.
See
Fig
.
5
.

ENGINE
REMOVAL
AND
INSTALLATION



110-
3

21
.
Remove
front
exhaust
pipefrom
exhaust
manifold
.
See

Fig
.
6
.

22
.
Install
an
engine
lifting
device
and
raise
engine
until
its

weight
is
supported
.
Remove
nuts
and
ground
strap

from
left
and
right
engine
mounts
.

0011967

Fig
.
6
.



Front
exhaustpipe
to
exhaust
mounting
nuts
(arrows),
as
viewed
from
below
on
4-cylinder
engine
.

23
.
Carefully
raíse
engine
out
of
car,
checking
for
any
wir-
ing
harnesses,
fuel
lines,
or
mechanical
parts
that
might
become
snagged
as
engine
is
removed
.

24
.
Installation
is
reverse
of
removal,
noting
the
following
:

"
Replace
all
gaskets,
O-rings
and
seals
.

"
Change
engine
oil
and
filter
and
check
al¡
other
fluid
levels
.
See020
Maintenance
Program
.
"
Refill
and
bleed
cooling
system
.
See
170
Radiator
and
Cooling
System
.

"
Insta¡¡
the
front
exhaust
pipes
using
new
gaskets
and

self-locking
nuts
.
Use
copper
pasteon
threads
.
See

180
Exhaust
System
.

Tightening
Torques

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

Fig
.
5
.
A/
C
compressor
mounting
bolts
(arrows)
.



"
Engine
mount
to
subframe

M8
......:...
..
..
..
......,:..
22
Nm
(17
ft
-
1b)
,

18
.
Move
A/C
compressor
out
of
way
without
distorting
or



M10
.
...
.



..
...
.
.
...........
45
Nm
(33
ft'-Ib)

damaging
any
lines
.
Support
compressor
by
hanging
it



"
Intake
manifold
to
cylinder
head

from
chassis
using
stiff
wire
.



M7
.....
.
..
...
..
..
...........
15
Nm
(11
ft-Ib)
M8
...
.
.
.
..
..
...
..
...........
22
Nm
(16
ft-Ib)

19
.
Disconnect
wiring
from
starter
and
alternator
.
Move



`
"
Radiator
cooling
fan
to
coolant
pump40
Nm
(30
ft-Ib)

wiring
harness
out
of
way
.
See
121
Battery,
Starter,



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

Alternator
.



"
Wiring
to
alternator
(M8
nut)
........
12
Nm
(9
ft-1b)

"
Wiring
to
starter

20
.
Remove
oil
dipstick
guide
tube
.
Note
O-ring
at
base
of



M6
nut
..
.
..
..
...
..
...........
.
:5
Nm
(44
in-lb)

tube
when
removing
.



M8
nut
..
.
..
..
...
..
............
12
Nm
(9
ft-Ib)

ENGINE
REMOVAL
AND
INSTALLATION

110-
4



ENGINE
REMOVAL
AND
INSTALLATION

Engine,
removing
and
installing

(6-cylinder
engines)

Engineremoval
procedures
for
the
various
6-cylinder
en-

gines
arecovered
in
this
section
.
Most
steps
in
theproce-

dures
are
similar
or
the
same
for
al¡
engines
.
Specific

differences
that
apply
are
noted
at
the
beginning
of
each
step
.

Be
sure
to
cover
all
painted
surfaces
before
beginning
the

removal
procedure
.
As
an
aid
to
installation,
label
all
compo-

nents,wires,
and
hoses
before
removing
them
.
Do
not
reuse

gaskets,
O-rings
or
seals
during
reassembly
.

WARNING
-

Due
to
risk
of
personal
injury,
be
sure
the
engine
is
cold
before
beginning
the
removalprocedure
.

1
.
Disconnect
negative
(-)
battery
cable
in
luggage
com-

partment
.

CAUTION-

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

2
.
Remove
engine
hood
or
place
hood
in
service
position
.

See410
Fenders,
Engine
Hood
.

NOTE-

1t
is
not
necessary
to
remove
the
engine
hood,
but
it
is
helpful
and
will
make
engine
removal
and
installation
easier
.

3
.
Remove
splash
guardunder
engine,
if
applicable
.

4
.
Remove
transmission
from
car
.
See
230
Manual

Transmission
or
240Automatic
Transmission
.

5
.
Remove
vacuum
hosefrom
brake
booster
on
bulkhead
.

Cover
hole
in
booster
and
plug
hose
end
.

6
.
Remove
intake
air
plenum
panel
in
rear
of
engine
com-
partment
.
See
640
Heating
and
AirConditioning
.

7
.
Remove
ground
strap
from
timing
case
cover,
if
appli-

cable
.

8
.
Remove
top
enginecovers
and
disconnect
ignition
coil
harness
connectors
.
Working
at
fuel
injectors,
pry
open
small
wire
clipsat
each
injector
.
Remove
main
harness

hold-down
nuts
and
lift
completeharness
away
.
See
Fig
.
7
.

ENGINE
REMOVAL
AND
INSTALLATION

Fig
.
7
.



Remove
mainharnessfrom
top
engine
and
place
at
base
of

windshield
.

0012703

Fig
.
8
.



Mass
air
flow
sensor
connector
air
duct
hose
clamp,
and
air
cleaner
housing
mounting
bolts
(arrows)
.

9
.
Unbolt
andremove
complete
air
cleaner
housing
with



10
.
On
cars
with
automatic
transmission,
remove
front
and
mass
air
flow
sensor,
disconnecting
and
labeling
con-



rearbrackets
holding
transmission
cooler
linesto
side
nectors,
ducting
and
hoses
asnecessary
.
See
Fig
.
8
.



of
engine
.

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

8
.
Remove
air
plenum
from
rear
of
engine
compartment
.
See
640
Heating
and
Air
Conditioning
.

9
.
Release
drive
belt
tension
and
remove
alternator
drive
belt
.
Remove
A/C
compressor
drive
belt
.
See
Fig
.
6
.

B11143
Fig
.
6
.



To
remove
poly-ribbed
drive
belt,
pry
cover
from
front
of
ten-
sioner
.
Then
using
8
mm
hex
key,
turntensioner
clockwise
(arrow)
torelease
tension
and
slip
belt
off
pulleys
.

10
.
Unbolt
power
steering
reservoir
and
pull
reservoir
off
engine
mount
bracket
.

11
.
Without
disconnecting
fluid
lines,
remove
power
steer-
ing
bracket
(with
pump)
from
oil
panand
engine
block
.
See
Fig
.
7
.
Disconnect
fluid
lines
from
bracket
on
en-
gine
mount
.
Hang
pump
from
chassis
using
wire
.

12
.
Without
disconnecting
refrigerant
lines,
remove
A/C
compressor
from
engine
block
.
Hang
compressor
from
chassis
using
wire
.
See
640
Heating
and
Air
Condi-
tioning
.

13
.
Remove
oil
dipstick
guide
tube
mounting
bolt
and
re-
move
tube
.
See
Fig
.
8
.

NOTE-

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

14
.
On
cars
with
automatic
transmission,
remove
brackets
holding
ATF
cooler
linesto
oil
pan
and
cylinder
block
.

LUBRICATION
SYSTEM



119-
5

Fig
.
7
.



Power
steering
pump
mounting
bolts
(arrows)
.

Fig
.
8
.



Oil
dipstick
guide
tube
being
removed
.
Usea
new
O-ring
(arrow)
during
installation
.

15
.
Insta¡¡
engine
lifting
equipment
at
front
engine
lifting
point
and
raise
engine
just
until
its
weight
is
supported
.

16
.
Remove
nuts
at
bottom
of
left
and
right
engine
mounts
.
Remove
ground
wire
from
right
engine
mount
.
1-oosen
nuts
at
top
of
left
and
right
engine
mounts
(do
not
re-
move)
.

OIL
PAN

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