Torques BMW 328i 1997 E36 Workshop Manual

GENERAL

FUNDAMENTALS
FORTHE
DO-IT
YOURSELF
OWNER



010-1

010
Fundamentals
for
the

Do-lt-Yourself
Owner

GENERAL
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.010-1



TOOLS
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010-8

Basic
Tool
Requirements
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010-8
HOW
TO
USE
THIS
MANUAL
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010-2



JackStands
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010-9

Warnings,
Cautions
and
Notes
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010-2



Oil
Change
Equipment
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010-9

GETTING
STARTED
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.010-2



Torque
Wrench
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010-10

Feeler
Gauges
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010-10
Safety



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010-2



Digital
Multimeter



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010-10
Lífting
the
Car
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010-3



gMW
Special
Tools
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010-11
Raising
car
safely
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010-3

Working
under
car
safely
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010-4



EMERGENCIES
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010-11

ADVICE
FOR
THE
BEGINNER
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010-4



Changing
a
Tire
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.010-11
Car
Will
Not
Start
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.010-11
Planning
Ahead
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010-4



Jump
Starting
Car
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010-12
Cleanliness
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010-4



Overheating



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010-12
Non-reusable
Fasteners
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010-5



Low
Oil
Pressure
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010-13
Tightening
Fasteners
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010-5



Brake
Fluid
Level



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010-13
Gaskets
and
Seals
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010-5



Check
Engine
Warning
Light
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010-13
Electrical
Testing
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010-6



pim
Lights
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010-13Wire
Repairs



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010-6



Towíng



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.010-13

BUYINGPARTS



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010-6



Spare
Parts
Kit
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010-14

Genuine
BMW
Parts
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010-6

Non-returnable
Parts
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010-7



TABLES

Information
You
Need
to
Know
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010-7



a
.
General
Bolt
Tightening
Torques

SERVICE
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010-7

Although
the
BMW
is
a
sophisticated
and
complex
machine,

basic
maintenance
can
be
accomplished
byan
interested
own-

er
with
mechanical
skills
and
the
right
information
.
Most
of
the

preventive
maintenance
that
is
required
in
the
lifetime
of
theav-

erage
BMW
is
weil
within
the
capabilitiesof
the
do-it-yourseifer
.

WARNING
-

Do
not
use
this
manual
unless
you
are
familiar
with

basicautomotive
repair
procedures
and
sale
work-
shop
practices
.
This
manual
illustrates
the
work-
shop
procedures
required
for
most
service
work
;it

is
not
a
substitute
for
full
and
up-to-date
information

from
the
vehicle
manufacturer
or
for
proper
training

asan
automotive
technician
.
Note
that
it
is
not
pos-

sible
for
us
to
anticipate
al¡
of
the
ways
orconditions
underwhich
vehicles
may
be
serviced
or
to
provide

cautions
as
to
all
of
the
possible
hazards
that
may

result
'

in
Nm
(max
.
permissible)
.
..
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.
010-5

WARNING
-

Your
common
sense
and
good
judgment
are
crucial
tosale
and
successful
service
work
.
Read
proce-
dures
through
before
starting
them
.
Thinkabout
whether
the
condition
ofyour
car,
your
leve¡
of
me-

chanical
skill,
or
your
leve¡
of
reading
comprehen-
sion
might
result
in
orcontribute
in
some
way
to
an
occurrence
that
might
cause
you
injury
damage
your
car,
or
result
in
an
unsafe
repair
.
lf
you
havedoubts
for
these
or
other
reasonsaboutyour
abilíty
to
perform
sale
repair
work
onyour
car,
have
the

work
done
at
an
authorized
BMW
dealer
or
other
qualified
shop
.

This
section
of
the
manual
is
intended
to
helpthe
beginner

get
started
.
To
begin
with
there
is
a
discussion
on
How
To
Use

This
Manual
.
Tips
on
mechanicas
skills
and
workshop
practic-

es
that
can
help
the
beginner
do
a
faster
and
more
thorough
job

can
be
foundunderGettingStarted
.
The
basic
tools
needed

to
do
most
of
the
procedures
in
this
manual
are
foundunder
Tools
.
The
section
ends
with
a
quick
reference
guide
to
Emer-
gencies,
including
basictroubleshooting
and
information
on
how
to
gauge
the
seriousness
of
a
problem
.

GENERAL

FUNDAMENTALS
FOR
THEDO-ITYOURSELF
OWNER



010-
5

WARNING
-

Avoid
getting
tools
or
clothing
near
the
battery
.
Bat-tery
electrolyte
is
a
corrosive
acid
.
Be
careful
with

brake
fluid,
as
it
can
damage
the
cars
paint
Finally,
keep
rubber
parts
such
as
hoses
and
bolts
free
from
oil
orgasoline,
as
they
will
cause
the
material
to
soften
and
fail
prematurely
.

Non-reusable
Fasteners

Many
fasteners
usedon
the
cars
coveredby
this
manual

mustbe
replaced
with
new
osesonce
they
are
removed
.
These



Fig
.
4
.
General
sequence
for
alternately
tightening
multiple
fasten-

include
butarenot
limited
to
:
bolts,
nuts
(self-locking,
nylock,



ers
.

etc
.),
cotterpins,
studs,
brake
fittings,
rol¡
pins,clips
and
wash-

ers
.
Genuine
BMW
parts
should
be
the
only
replacement
parts



NOTE-

used
for
this
purpose
.



"
Metric
bolt
classes
or
grades
are
markedon
the
bolt'

head
.

Some
bolts
are
designed
to
stretch
during
assembly
and
are

permanently
altered
rendering
them
unreliable
once
removed
.

These
are
known
as
torque-to-yield
fasteners
.
Always
replace
fasteners
where
instructed
to
doso
.
Failure
to
replace
these

fasteners
could
cause
vehicle
damage
and
personal
injury
.

See
an
authorized
BMW
dealer
for
applications
and
ordering

information
.

Tightening
Fasteners

When
tighteningthe
bolts
ornuts
that
attach
acomponent,
it

is
always
good
practice
to
tighten
the
bolts
gradually
and
evenly

to
avoid
misalignment
or
over
stressing
anyone
portion
of
the

component
.
For
components
sealed
with
gaskets,
this
method

helps
to
ensure
that
thegasket
will
seal
properly
and
complete-

ly
.

Where
there
are
severa¡
fasteners,
tighten
them
in
a
se-

quence
alternating
between
opposite
sides
of
the
component
.

Fig
.
4
shows
such
a
sequence
for
tightening
six
bolts
attaching

a
typical
component
.
Repeat
the
sequence
until
al¡
the
bolts
are
evenly
tightened
to
theproper
specification
.

"
Do
not
confuse
wrench
sizewithbolt
diameter
size
.
Fora
listing
of
the
common
wrenches
used
on
vari-
ous
bolt
diameters,
see
Basic
Tool
Requirements
.

Table
a
.
General
Bolt
Tightening
Torques
in
Nm

(max
.
permissible)

Bolt
Class
(according
to
DIN
267)
Bolt
diameter
5
.6
5
.8
6
.8
8
.8
10
.9
12
.9

M5
2
.5
3
.5
4
.5
6810

M6



4
.5



6



7
.5



10



14
`
17

M8



11



15
-



18



24



34



40

M10
233036476679

M12
3952
62
82115140

M14
6282
98
130
180220

M16
9426150
200280340

M18
130174210280
390
470

For
some
repairs
a
specific
tightening
sequence
is
neces-

sary,
or
a
particular
order
of
assembly
is
required
.
Such
special



Gaskets
and
Seals

conditions
are
noted
in
the
text,
and
the
necessary
sequence
is

described
or
illustrated
.
Where
no
specific
torque
is
listed,
Ta-



The
smoothest
metal
mating
surfaces
still
have
imperfec

blea
can
be
used
as
a
general
guide
for
tightening
fasteners
.



tions
that
can
allow
leakage
.
To
prevent
leakage
atcritica¡

joints,
gaskets
of
soft,
form-fitting
material
are
used
to
fill
in
the

WARNING
-



imperfections
.
Table
ais
a
general
reference
only
.
The
values
list-

ed
in
the
table
are
not
intended
to
be
used
asa
sub-



To
be
most
effective,
gaskets
are
designed
to
crush
and
be-
stitutefor
torques
specifically
called
out
in
the
text



come
thinner
as
the
mating
parts
are
bolted
together
.
Once
a
throughout
this
manual
.



gasket
has
been
used,
it
is
no
longer
capable
of
makingas

good
a
sea¡
as
when
new,
and
is
muchmore
likely
toleak
.
For

this
reason,
gaskets
should
not
be
reused
.
Always
plan
to
use

new
gaskets
for
any
reassembly
.
Some
gaskets-such
as
head
gaskets-are
directional
.
Make
sure
that
these
are
in-

stalled
correctly
.
This
same
logic
applies
to
any
part
used
for

sealing,
including
rubber
O-rings
and
copper
sealing
washers
.

ADVICE
FOR
THE
BEGINNER

Fig
.
16
.
Multimeter
or
Digital
Volt/Ohmmeter
(DVOM)
.

BMW
Special
Tools

FUNDAMENTALS
FOR
THE
DO-ITYOURSELF
OWNER
010-11

0012223

Some
of
the
more
challenging
repairs
covered
in
this
manual

cal¡
for
the
use
of
BMW
special
tools
.
This,
however,
does
not

automatically
mean
that
thejob
is
too
complicated
or
out
of

reach
of
thenovice
.

Many
of
the
BMW
special
tools
mentioned
in
this
manual
are
simplythe
best
thing
to
use
to
do
thejob
correctly
.
In
these
cas-

es,
the
tool
is
identified
with
a
BMW
part
number
.
See
your
au-

thorized
BMW
dealer
parts
department
for
information
on
how

to
order
special
tools
.

There
are
some
jobs
for
which
expensive
special
tools
are

essential,
and
not
a
cost-effective
purchase
for
one-time
repair

by
the
do-it-yourself
owner
.
This
manual
includes
such
repairs

for
the
benefit
of
these
with
the
necessary
experience
and
ac-

cess
to
tools
.
For
the
do-it-yourselfer,
the
need
for
special
tools

is
noted
in
the
text,
and
whether
or
not
BMW
dealer
service
is

recommended
.

EMERGENCIES

Changing
a
Tire

Stop
thecar
onas
flat
a
surface
as
possible,
in
a
place
where

you
canbe
easily
seen
by
other
drivers
.
Avoid
stopping
just

over
the
crest
of
a
hill
.
Turnon
the
emergency
flashers,
and
set

out
(lares
or
emergency
markers
well
behindthecar
.
Chock
the

wheel
(wheel
chock
located
in
trunk)
diagonally
opposite
to
the
one
being
changed
.
Passengers
shouldgetout
of
thecar
and

stand
well
away
from
the
road
.
Remove
the
spare
tire
from
the
spare
tire
storage
tray,
as
described
later
.

WARNING
-

If
a
tire
goes
fíat
while
drtving,
pull
well
off
the
road
.
Changing
a
tire
ona
busy
street
or
highway
is
very
dangerous
.
If
necessary,
drive
a
short
distance
on
the
fíat
tire
to
get
to
a
sale
place
.
tt
is
much
better
to
ruin
a
tire
or
rim
than
to
risk
being
hit
.

Take
the
jack
and
tools
from
the
tool
area
beneath
the
trunk

mat
.
Remove
the
spare
tire
from
the
tire
storage
tray
.

Loosen
the
wheel
bolts
while
the
car
is
on
the
ground,
but

leave
them
a
little
snug
.
Placethe
jack
in
the
lifting
point
nearest

the
wheel
beingchanged,
lifting
points
are
shown
in
Fig
.
1
and

Fig
.
2)
.
Use
a
board
to
provide
a
firm
footing
for
the
jack
if
the

ground
is
soft
.
Raise
the
car
only
lar
enough
so
that
the
wheel
is

fully
off
the
ground
and
then
remove
the
wheel
nuts
and
the

wheel
.

Insta¡¡
the
spare
wheel
.
Install
the
wheel
nuts
and
tighten

them
by
hand,
then
lower
the
car
.
With
all
wheelson
the

ground,
fully
tighten
the
nuts
in
a
crisscross
pattern
.
Torque
the

wheel
nuts
when
installing
the
wheel
.
Check
the
inflation
pres-

sure
of
the
spare
tire
.

Tightening
torques

"
Wheel
to
wheel
hub
.....
100
t
10
Nm
(74
t
7
ft-Ib)

Car
Will
Not
Start

If
the
engine
tucos
over
slowly
or
not
at
all,
especially
on
cold

mornings,
the
battery
may
not
be
sufficiently
charged
.
Jump-

starting
the
battery
from
another
car
may
help
.

WARNING
-

On
carswith
manual
transmisston,
push
starting
(or

tow
starting)
acar
ts
not
recommended
by
BMW
.

NOTE-

Be
sure
to
read
the
cautions
underJump
Starting
Car
prior
boosting
a
low
battery
.
Fatlure
to
followthe
cau-

tions
may
result
in
damage
to
the
electronic
compo-
nents
in
the
car
.

If
the
engine
is
turning
over
at
normal
speed
with
the
starter

motor,
the
battery
and
starter
are
fine
.
Check
to
make
sure
that

there
is
fuel
in
the
tank
.
Do
not
rely
on
the
fuel
gauge,
it
may
be

faulty
.
Instead,
remove
the
gas
filler
cap
and
rock
thecar
.
If

there
is
gas
in
the
tank,
you
should
hear
a
sloshing
sound
at
the

filler
neck
.
lf
there
is
plenty
offuel
in
the
tank,
see100
Engine-

General
for
in-depth
diagnostics
and
troubleshootingproce-

dures
.

EMERGENCIES

Final
Drive
Gear
Oil

BMW
recommends
using
only
a
specially
formulatedsyn-
thetic
gear
oil
that
is
available
through
an
authorized
BMW
dealer
parts
department
.
For
additional
information
on
this
¡u-
bricant
andany
other
lubricants
that
may
be
compatible,
con-
tact
an
authorized
BMW
dealer
senrice
department
.
See
331
Final
Drive
.

Brake
Fluid

Brake
fluid
absorbs
moisture
easily,
and
moisture
in
the
fluid
affects
brake
performance
and
reliability
.
This
is
why
brake
fluid
should
be
flushed
from
the
system
every
two
years
.
When
re-
placing
or
adding
brake
fluid,
use
only
new
(luid
from
previously
unopened
containers
.
Do
not
use
brake
fluid
that
has
been
bled
from
the
system,
even
ifit
is
brand
new
.
Use
only
DOT
4
brake
fluid
.
See340
Brakes
for
more
information
.

Engine
Coolant
(Anti-freeze)

BMW
recommends
coolant
that
is
a
50/50
mixture
of
distilled
water
and
phosphate/nítrate
freeanti-freeze
containing
ethyl-
ene
glycol
.
Anti-freezeraises
the
boiling
point
and
lowersthe
freezingpoint
of
the
coolant
.
It
alsocontains
additives
that
help
prevent
cooling
system
corrosion
.

Power
Steering
Fluid

The
power
steering
fluid
is
Dexron
II]®
ATF,
or
equivalent
.

The
system
is
permanently
filled
and
does
not
have
a
drain
.
Routinely
adding
ATF
is
not
required
unlessthe
system
is
leak-
i
n
g,

WARNING
-

Be
sure
to
check
the
fluid
specifications
on
the
pow-
er
steering
reservoir
to
confirm
the
fluid
type
in-
stalled
in
the
system
.
In
some
instances,
the
power
steering
system
may
be
filled
with
an
alternative
hy-
draulic
fluid
designated
CHF
7
.1
.

MAINTENANCE
PROGRAM
020-

ENGINE
OIL
SERVICE



Engine
oil
and
fiiter,
changing

Fig
.
3
.



Engine
oil
level
dipsticklocation
on
4-cylinder
engine
(arrow)
.
Dipsfck
is
marked
with
mínimum
and
maximum
level
marks
.

Fig
.
4
.



Oil
filler
cap
(arrow)
.
6-cylinder
engine
shown
.
0012202

Engine
oii,
checking
leve¡



A
complete
oil
change
requires
new
oil
(see
Table
e),
a
new
oil
filter
insert
kit,
and
a
new
drain
plug
sealing
washer
.
The

The
engine
oil
leve]
is
checked
with
a
dipstick
in
the
engine



tools
needed,
a
drain
plug
socket
or
box
wrench
(17
mm
or19

block
.
Check
the
oii
leve¡
with
the
canon
a
level
surface,
after



mm)
and
a
drain
pan
(8-10
US
qt
.
capacity),
are
described
in

the
engine
has
been
stopped
for
atleast
a
few
minutes
.
Check



010
Fundamentals
for
the
Do-It-Yourself
Owner
.

the
leve¡
by
pulling
outthe
dipstick
and
wiping
it
clean
.
Reinsert

it
all
the
way
and
withdraw
it
again
.
The
oil
leve¡
is
correct
if
it
is



NOTE-
between
the
two
marks
near
the
end
of
the
stick
.
See
Fig
.
3
.



If
using
a
"fast-lube"
service
facility
for
oil
changes,
make
sure
the
technician
hand-starts
and
torques
the
Add
oil
through
the
filler
cap
on
thetop
of
the
cylinder
head
.



engine
oil
drain
plug
using
hand-tools
.
Power
tools
can
See
Fig
.
4
.
Add
only
the
amount
needed
to
bring
the
oil
leve¡to



strip
the
threads
of
the
plug
and
the
oil
pan
.

the
MAX
mark
on
the
dipstick,
using
an
oil
of
the
correctviscos-
ity
andgrade
.
Too
much
oil
canbe
just
as
harmful
as
too
little
.

ENGINE
OIL
SERVICE

020-
1
0



MAINTENANCE
PROGRAM

1.
Run
engine
for
afewminutes
to
warm
engine
oil
.
Shut



5
.
When
oil
flow
has
diminished
to
an
occasional
drip,
re-

engine
off
.



install
drain
plugwith
a
new
metal
sealing
washerand

torque
plug
.

2
.
With
car
on
level
ground,
place
drain
pan
under
oil
drain

plug
.
See
Fig
.
5
.



Tightening
Torques

"
Engine
oil
drain
plug

M12
bolt
(17mm
wrench)
.
...
.
..
.
25
Nm
(18
ft-Ib)



-

M22
bolt
(19mm
.
wrench)
...
.
...
.
60
Nm
(44
ft-Ib)

Fig
.
5
.



Engine
oil
drain
plug(arrow)
in
oil
pan
.

3
.
Remove
filter
housingcover
.
Remove
filter
cartridge

and
discard
any
O-rings
.
See
Fig
.
6
.

CAUTION-

Pulí
the
loose
plug
away
from
the
hole
quickly
to
avoidbeing
bumed
by
hot
oil
.
It
wíll
runout
quickly
when
the
plug
ís
removed
.
If
possible,
use
gloves
to
protect
your
hands
.

ENGINE
COMPARTMENT
MAINTENANCE

0012460

Fig
.
6
.



Engine
oil
filter
cartridge
.
Note
O-ring
locations
when
removing
cover
and
filter
.

4
.
Using
a
socket
or
box
wrench,
loosen
drain
plug
at
oil

drain
pan
.
By
hand,
remove
plug
and
letoil
drain
into

pan
.

6
.
Lubricate
and
install
new
O-rings
.
Install
a
new
filter

cartridge
and
housingcover
.
Tighten
cover
.
See
Fig
.
7
.

7



«
a~
.~~
fT~

iII~IIIi~
.

Fig
.
7
.



Oil
flter
housing
on
6-cylínder
engine
.
4-cylinder
engine
is

similar
.

Tightening
Torque

"
Engine
oil
filter
cover
to
oil

filter
housing
...................
25
Nm
(18
ft-Ib)

7
.
Refill
crankcase
with
oil
.'Approximate
oil
capacity
is
list-

ed
in
Tablee
.
Use
dipstick
to
check
correct
oil
level
.

8
.
Start
engine
and
check
that
oil
pressure
warning
light

immediately
goes
out
.

9
.
Allow
engine
to
run
for
a
few
minutes
to
círculate
new

oil,
then
check
for
leaks
at
drain
plug
and
oil
filter
.
Stop

engine
and
reclieck
oil
level
.

ENGINE
COMPAR



ENT
MAINTENANCE

The
information
underthis
heading
describes
routine
mainte-

nance-other
than
oil
change-done
in
the
engine
compart-

ment
.
It
is
not
necessary
for
the
car
to
be
raised
and
supported
off
the
ground
.
Information
on
oil
change
is
given
earlier
under

Engine
Oil
Change
.

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

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

22
.
Move
A/C
compressor
out
of
the
way
without
distorting



26
.
Carefully
raise
engine
out
ofcar,
checking
for
any
wir-
or
damaging
any
lines
.
Support
compressor
by
hanging



ing,fuel
lines,
or
mechanical
parts
that
might
become
it
from
chassis
using
stiff
wire
.



snagged
as
engine
is
removed
.

23
.
Disconnect
wiring
from
starter
and
alternator
.
Move



27
.
Installation
is
reverse
of
removal,
noting
the
following
:
wiring
harness
out
of
the
way
.
See
121
Battery,
Start-
Replace
al¡
gaskets,
O-rings
and
seals
.
er,
Alternator
.



"
Change
engine
oil
and
filter
and
check
all
other
fluid

24
.
Remove
Fontexhaust
pipe
fromexhaust
manifold
.
See



levels
.
See
020
Maintenance
Program
.
"
Refill
and
bleed
cooling
system
.
See
170
Radiator
Fig
.
16
.



and
Cooling
System
.

"
Check
that
engine
drivebelts
properly
engage
the
pul-

ley
grooves
.

"
Install
the
Font
exhaust
pipesusing
new
gaskets
and
seif-locking
nuts
.
Use
copper
paste
on
threads
.
See
180
Exhaust
System
.

0012525

Fig
.
16
.
Front
exhaust
pipeto
exhaust
manifolds
mounting
nuts
on
6-

cylinder
engine
(arrows)
.

25
.
Install
an
engine
lifting
device
and
raise
engine
until
its

weight
is
supported
.
Remove
nuts
and
ground
strap

from
left
and
right
engine
mounts
.

ENGINE
REMOVAL
AND
INSTALLATION



110-
7

Tightening
Torques

"
Coolant
drain
plug
to
cylinder
block
.
25
Nm
(18
ft-Ib)
"
Engine
mount
to
subframe
M10
..
.
.
.
...
..............
..
.
45
Nm
(33
ft-Ib)

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

"
Intake
manifold
to
cylinder
head

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

M8
...
.
..
...
................
.
22
Nm
(16
ft-Ib)
"
Radiator
cooling
fan
to
coolant
pump40
Nm
(30
ft-Ib)

"
Radiator
drain
screw
to
radíator
...
2
.5
Nm
(22
in-lb)
"
Wiring
to
alternator
(M8
nut)
........
12
Nm
(9
ft-Ib)

"
Wiring
to
starter

M6
nut



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

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

ENGINE
REMOVAL
AND
INSTALLATION

7
.
Lightly
lubricate
new
cylinder
head
bolts
.
Loosely
instan
bolts
and
their
washers,
then
thread
them
in
until
they
are
finger
tight
.

NOTE-

Check
that
all
washers
for
the
cylinder
head
bolts
are
in
place
before
installing
the
bolts
.

8
.
Tighten
cylinder
head
bolts
in
correct
sequence
.
See
Fig
.
17
.

UU125U2

Fig
.
17
.
Cylinder
head
bolt
tightening
sequence
for
4-cylinder
en-
gines
.
Note
oil
supply
tube
seal
(arrow)
on
M44
engine
.

WARNING
-

The
bolts
should
be
tightennd
in
three
stages
as
líst-
ed
below
.
The
final
stages
require
the
use
of
a
spe-

cial
tool
(BMW
tool
No
.
11
2
110)
ora
suitable

protractor
to
tighten
the
bolts
to
a
specified
torqueangle
.
See
Fig
.
18
.

Tightening
Torques

"
Cylinder
head
to
engine
block
(Torx
El2
M10
bolts)

Stage
1



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

Stage
2



.
...
...
.
.
...................
..
.
+90°

Stage
3
.....
...
.
..
...................
..
+90°

9
.
Carefully
rotate
crankshaft
in
direction
of
engine
rota-
tion
and
lock
it
at
TDC
by
inserting
BMW
special
tool

no
.
11
2
300
through
transmission
bellhousing
.
See

Fig
.
19
.

CYLINDER
HEAD
REMOVAL
AND
INSTALLATION



113-
7

Fig
.
18
.
Protractor
and
pointer
being
used
to
tighten
bolts
to
specified
torqueangle
(6-cylinder
engine
shown)
.

Fig
.
19
.
BMW
special
tool
11
2
300
inserted
through
bellhousing
hole
and
finto
flywheel
(arrow)
to
lockcrankshaft
at
TDC
.

10
.
Turn
left
chainguide
adjusting
sleeve
in
until
it
just
con-

tacts
the
cylinder
head
(See
Fig
.
14
.)
.
Insert
chain
guide
retaining
screw
and
tighten
.

CAUTION-



11
.
Placechain
sprockets
with
chains
oncamshaftsso
that
Be
sure
timing
chain
does
not
bind
oncrank
gear

when
turning
crankshaft
.



arrowson
sprockets
point
up
and
elongated
holes
in

sprocketsare
centered
to
tapped
holes
in
camshafts
.

See
Fig
.
20
.

CYLINDER
HEAD,
4-CYLINDER

113-10



CYLINDER
HEAD
REMOVAL
AND
INSTALLATION

Tightening
Torques

"
Coolant
drain
plug
to
cylinder
block
.
.
25
Nm
(18
ft-1b)

"
Intake
manifold
support
to
manifold
.
.
15
Nm
(11
ft-Ib)

"
Lower
intake
manifold

to
cylinder
head
.
..........
.
..
...



15
Nm
(11
ft-Ib)

"
Lower
intake
manifold

to
upper
manifold
..........
.
..
...
15
Nm
(11
ft-Ib)

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

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

CYLINDER
HEAD,
6-CYLINDER

For
ease
of
use
this
procedure
is
broken
into
subsections,

as
follows
:

General
Coolingsystem,
draining
Cyiinder
head
cover,
removing

Intake
manifold,
removing

Timing
chains,
uncoupling

Cylinder
head
assembly,
removing

WARNING
-

Allow
the
engine
to
cool
before
beginning
this
pro-
cedure
.

General

1
.
Working
inside
luggage
compartment,
disconnect
neg-
ative
(-)
battery
cable
.

CAUTION-

"
Prior
to
disconnectiog
the
battery,
read
the
bat-
tery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
vi¡¡
.

"
Disconnecting
the
battery
may
erase
fault
code(s)
stored
in
control
module
memory
.
Check
for
fault
codes
using
special
BMW
diagnostic
equipment

2
.
Remove
front
exhaust
pipes
from
manifolds
.
Discard
nuts
.

3
.
Remove
air
filter
housing
complete
with
mass
air
flow
sensor
and
intake
air
ducting
.
Disconnect
vacuum
hos-
es
from
throttle
housing
.

4
.
On
M52
and
S52US
engines
:
Remove
secondary
air
injection
check-valve
from
front
of
engine
and
set
aside
.

CYLINDER
HEAD,
6-CYLINDER

Coolingsystem,
draining

5
.
Drain
engine
coolant
and
Rmove
coolant
hoses
from

thermostat
housing
.
Drain
engine
block
by
removing

block
drain
.
See
170
Radiator
and
Cooling
System
.

NOTE-

The
block
drain
is
on
the
exhaust
side
of
the
engine,
near
cylinder
no
.
5
.

6
.
Remove
radiator
cooling
fan
and
fan
shroud
.
See
170

Radiator
and
Cooling
System
.

NOTE-

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

Cylinder
head,
removing

(6-cylinder
engine)



7
.
Disconnect
heater
hoses
at
rear
of
cylinder
head
.
See

Fig
.
26
.

'i

8
.
Remove
alternator
cooling
duct
.

Cylinder
head
cover,
removing

0012687

Fig
.
26
.
Disconnect
heater
hoses
at
heater
valve
(A)
and
heater
core
(B)
.

9
.
Remove
air
plenum
from
rear
of
engine
compartment
.

See640
Heating
and
Air
Conditioning
.

10
.
Remove
plastic
cylinder
head
covers
from
above
fuel
injectors
and
ignition
coils
.
Pull
larger
cover
forward

when
removing
.
See
Fig
.
27
.

11
.
Disconnect
crankcase
ventílation
hose
fitting
from
cyl-
inder
head
cover
.

12
.
Disconnect
ignition
coil
harness
connectors
from
coiis
.

Remove
ignition
coiis
and
spark
plugs
.
See
120
Igni-
tion
System
.