torque BMW M3 1998 E36 Repair Manual

130-
2
2



FUEL
INJECTION

Mass
air
flow
sensor,
replacing

1
.
Disconnect
harness
connector
and
intake
air
bootfrom

air
flow
sensor
.
See
Fig
.
32
.

Fig
.
32
.
To
detach
air
flow
sensor,
disconnect
harness
connector
(A)
;



3
.
Installation
is
reverse
of
removal
.
unclip
retainíng
clips
to
aír
filter
housing
(B)
;
andremove
large
hose
clamp
at
air
intake
bellows
(C)
.
M44
engine
with
traction



"
Use
a
new
copper
sealing
washer
when
installing
sen-

control
shown
.



sor
.
"
Replace
any
lost
coolant
.

2
.
Detachtwo
large
clipsat
air
filter
housing
and
work
air

flow
sensor
out
of
rubber
seal
in
filter
housing
.
Tightening
Torque

3
.
Installation
is
reverse
of
removal
.



"
Engine
coolant
temperature

"
For
ease
of
installation,
lubricate
large
rubber
seal
in



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

air
filter
housing
with
silicone
lubricant
or
equivalent
.
"
No
adjustment
to
air
flow
sensor
is
possible
.
"
Carefully
check
that
all
hoses
and
seals
are
seated



Intake
air
temperature
(IAT)
sensor,

properly
.



replacing

Engine
coolant
temperature
(ECT)
sensor,

replacing

The
engine
coolant
temperature
(ECT)sensor
is
a
dual
temperature
sensor
.
One
circuít
provides
coolant
temperature

information
to
the
ECM
while
the
other
circuít
provides
coolant
temperature
information
to
the
instrument
cluster
.

WARNING
-

Do
not
replace
the
ECT
sensor
unless
the
engine
is
cold
.
Hot
coolant
can
scald
.

1
.
Disconnect
harness
connector
from
ECT
sensor
.
See
Fig
.
33
.

2
.
Unscrew
temperature
sensorfrom
cylinder
head
and
remove

BOSCH
DME
M5
.2
COMPONENT
REPLACEMENT

U1111
bis4a

Fig
.
33
.
M44
engine
coolant
temperature
(ECT)
sensor
located
above

oil
filter
(arrow)
.

The
intake
air
temperature
(IAT)
sensoron
cars
with
M44

engine
is
mounted
in
thetop
section
of
the
intake
air
filter

housing
.
See
Fig
.
34
.

1
.
Remove
electrical
harness
connector
from
IAT
sensor
.

2
.
Unclip
temperature
sensor
and
remove
from
air
filter

housing
.

3
.
Installation
is
reverse
of
removal
.

Throttle
position
sensor
(TPS),
replacing

The
throttle
position
sensor
is
located
on
the
side
of
the
throttle
housing
.
See
Fig
.
35
.

1
.
Unplug
harness
connector
from
sensor
.

Mass
air
flow
sensor,
replacing

1
.
Disconnect
harness
connector
and
intake
air
boots

from
air
flow
sensor
.
See
Fig
.
37
.

Fig
.
37
.
Mass
air
flow
sensor
(arrow)
on
M52
engine
.

2
.
Installation
is
reverse
of
removal
.

"
No
adjustment
to
aír
flow
sensor
is
possible
.

"
Check
intake
hoses
for
cracks
and
vacuum
leaks
.

Engine
coolant
temperature(ECT)
sensor,

replacing

The
ECT
sensor
is
a
dual
temperature
sensor
.
One
circuit

provides
coolant
temperature
information
to
the
ECM
while

the
other
circuit
provides
coolant
temperature
information
to

the
instrument
cluster
.

1
.
Remove
left-side
top
engine
cover
.

4
.
Remove
sensor
.

5
.
Installation
is
reverse
of
removal
.

"
Replace
any
lost
coolant
.

0012703

"
Use
a
new
copper
sealing
washer
when
installing
new

Tightening
Torque

"
Engine
coolant
temperature

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

FUEL
INJECTION



130-
25

0012704b

Fig
.
38
.
M52
engine
:
Engine
coolant
temperature
(ECT)
sensor
(A)
is
located
beneath
top
engine
cover
(8)
and
crankcase
vent

hose
(C)
.

Intake
air
temperature
(IAT)
sensor,

replacing

The
intake
air
temperature
(IAT)
sensor
for
the
M52/S52US

engine
is
mounted
on
the
bottom
of
the
intake
manifold
.
See
Fig
.

39
.

2
.
Unclip
crankcase
venting
hose
from
cylinder
head
cov-

er
.
See
Fig
.
38
.



Fig
.
39
.
M52/S52US
engine
:
Intake
air
temperaturesensor
location
in

bottom
of
intake
manifold(arrow)
.
Throttle
housing
shown
re

3
.
Under
intake
manifold,
disconnect
harness
connector



moved
.

fromsensor
.

1
.
Disconnect
intake
air
bootfrom
throttle
housing
.
Unbolt

throttle
housing
and
¡ay
aside
.
(It
is
not
necessary
to

disconnect
throttle
cable
or
electrical
harnessconnec-

tors
from
throttle
housing
.)

sensor
.



2
.
Remove
electrical
harness
connector
from
IAT
sensor
.

3
.
Unclip
temperature
sensor
and
remove
from
intake

manifold
.

4
.
Installation
is
reverse
of
removal
.
Use
a
new
gasket
at

the
throttle
housing
.

SIEMENS
MS
41
.1
COMPONENT
REPLACEMENT

160-
4



FUEL
TANK
AND
FUEL
PUMP

Fig
.
4
.



Pinch
off
supply
and
retum
fuel
hoses
(arrows)
before
dis-
connecting
from
rigid
metal
lines
.

0013143

Fig
.
5
.
After
removing
exhaustsystem,
remove
heat
shield
screws
(arrows)
and
heat
shield
.

9
.
Working
underneath
car,
loosen
hose
clamp
and
dis-

connect
filler
hose
.

10
.
Support
tank
from
below
.
Remove
tank
strap
mounting

bolts
.
Lower
and
remove
tank,
disconnecting
right
side



TheE36
model
uses
a
two-lobed
fuel
tank
and
each
lobeof
vent
and
other
hoses/electrical
connectors
as
neces-



the
tank
has
its
own
fuel
level
sending
unit
.
sary
.

11
.
Installation
is
reverse
of
removal
.

"
Always
use
new
seals,
gaskets,
O-rings,
and
hose
clamps
.

"
Inspect
hoses
and
replace
any
that
are
chafed,
dried

outor
cracked
.

"
Inspect
heat
shield
and
replace
if
corroded
.

"
Inspect
rubber
buffers
and
liners
on
fuel
tank,
support
straps
and
on
underside
of
body
.
Replace
rubber

parts
that
are
hardened
or
damaged
.

FUEL
LEVEL
SENDERS

CAUTION-

"
Before
starting
the
engine,
fill
the
fuel
tank
with
at
least
1.5
gallons
(5
liters)
of
fuel
to
prevent

damaging
a
dry
fuel
pump
.

"
If
the
filler
neck
has
been
removed
from
the
body,
be
sure
toreattach
theneck's
grounding
screw
(where
applicable)
.
Check
electrical
resistance
between
the
ground
tab
and
wheel
hub
.
The
re-
sistance
shouldbeno
higher
than
0
.6
ohms
.

Tightening
Torques

"
Fuel
tank
to
body
.............
...
23
Nm
(17
ft-Ib)

"
Hose
clamps
(10
mm-16
mm
día
.)
..
2
.0
Nm
(18
in-lb)

Fuel
Tank
Evaporative
Control
System

The
fuel
tank
evaporative
control
system
is
used
to
vent
the

fuel
tank
to
a
charcoal
canister,
which
is
then
purgedby
en-

gine
vacuum
during
normal
engine
operatíon
.
This
controls

emission
of
raw
hydrocarbons
(fuel)
to
the
atmosphere
.
See

Fig
.
1
.

A
fuel
expansion
tank,
located
under
the
right
rear
fender,

traps
overflow
fuel
and
incorporates
extra
fuel
tank
plumbing
.

Startingwith
1996
models,
OBD
II
standards
require
that

the
fuel
tank
evaporative
control
system
be
monitored
for

leaks
.
This
is
accomplished
usingthe
fuel
tankpressuresen-

sor,
the
ventshut
off
valve,
and
the
evaporative
purge
valve
.

NOTE-

On
most
early
cars(1992-1995),
the
charcoal
canister

is
in
the
engine
compartment
.
On
latercars,
the
char-
coal
canister
is
under
the
spare
tire
in
the
luggage
com-
partment
.

FUEL
LEVEL
SENDERS

The
right
side
fuel
leve¡
sender
is
integrated
with
the
fuel

pump
.
Each
senderhas
a
float
connected
to
a
variable
resis-

tance
for
fuel
leve¡
.
When
replacing
the
sender/pump
assem-

bly
always
replace
hose
clamps,gaskets
and
O-rings
.

WARNING
-

When
removing
the
fuel
level
sender
or
the
fuel
pump,
the
fuel
tank
should
be
emptied
.

170-
4



RADIATOR
AND
COOLING
SYSTEM
A
quick
testat
the
coolant
temperature
gauge
sender
can



The
auxiliary
cooling
fan
comes
on
when
coolant
tempera

determine
if
the
gauge
is
functioning
correctly
.



ture
exceeds
a
predetermined
leve¡
or
whenever
the
air
condi-

tioning
is
on
.
A
dual-range
temperature
switch
for
cooling
fan
lf
the
gauge
needie
remains
at
the
rest
position
with
theen-



control
is
mounted
on
the
right
side
of
the
radiator
.
See
Fig
.
3
.
gine
warm,
remove
the
harness
connector
from
the
sender
and
jumper
the
correct
terminals
in
the
connector
to
simulate
a
high
engine
temperature
.
See
Table
a
.
Turn
the
ignition
on
.

If
the
gauge
needle
moves
upward,
the
sender
is
faulty
.
If
the

gauge
does
not
respond,
the
wiring
to
the
gauge
is
broken
(open
circuit)
or
the
gauge
itselfis
faulty
.

WARNING
-

1996
and
laten
models
are
OBD
11
compliant
.
Dis-
connecting
electrical
connectors
wíth
the
ignition
turned
on
may
set
fault
codes
in
the
ECM
.
It
is
rec-
ommended
that
you
leave
the
diagnosis
of
faults
in
the
coolant
temperature
sensorsystem
to
the
BMW
dealer
service
department
which
has
specialized
OBD
11
scan
tool
equipment
.

If
the
gauge
needle
reads
too
high
when
the
engine
is
cold,
remove
the
harness
connector
from
the
sender
.
Turn
the
igni-

tion
on
.
lf
the
gauge
needle
position
does
not
change,
the
wir-

ing
or
the
gauge
is
shorted
to
ground
.
If
the
gauge
needle

drops,
the
sender
is
faulty
and
should
be
replaced
.
When
re-

placing
a
faulty
coolant
temperature
sender,
the
gasket
ring
on
the
sender
should
also
be
replaced
.

Tightening
Torque

"
Temperature
gauge
sender
to
engine
18
Nm
(13
ft-Ib)

Cooling
fan,
testing

NOTE-

OnM44
engines
with
manual
transmission,
the
primary
electric
cooling
fan
is
mounted
on
the
engine
side
of
the
radiator
and
is
controlled
by
the
engine
control
module
(ECM)
.
Troubleshooting
thiscircuit
should
be
left
to
an
authorized
BMW
dealer
with
the
proper
diagnostic
equipment

An
otherwise
sound
cooling
system
may
still
overheat,
par-
ticularly
with
prolonged
idling,
due
to
a
failure
of
the
coolíng

fan(s)
.

The
belt-driven
cooling
fan
is
controlled
by
a
temperature
dependent
viscous
clutch
.
A
failed
fan
clutch
may
affect
air
flow
through
the
radiator
resulting
in
overheating
orpossibly
overcooling
.
Speed

Low
sp
High
s

With
the
engine
off,
check
thefan
clutch
by
spinning
thefan
.



eed
The
fan
should
spin
on
the
clutch
with
some
resistance
.



peed
Check
for
signs
of
leaking
fluid
from
the
clutch
.
If
thefan
free-
wheels
with
no
resistance,
cannot
be
tu
rned
by
hand,
or
there
are
signs
of
oil
leakage,
the
clutch
should
be
replaced
.

TROUBLESHOOTING

Fig
.
3
.



Radiatorcooling
fan
temperature
switch
(arrow)
.

WARNING
-

"
Use
caution
when
testing
the
electric
cooling
fan(s)
and
coolant
temperature
switch
.
Keep
hands
and
wires
clear
of
thefan
blades
.
The
cool-
ing
fan(s)
can
run
any
time
the
ignition
is
ON
.

"
For
greatest
safety,
coolíng
fan
and
coolant
tem-perature
switch
tests
shouldbe
performed
on
acoldengine
with
the
air
conditioning
off
.

Table
b
.
Auxiliary
Cooling
Fan
Switching

Temperatures

Switching
temperature
196°F(91°C)
210°F(99°C)

0012506

If
a
faulty
thermostat,
trapped
air,
or
a
restriction
in
the
sys-
tem
is
not
allowing
the
coolant
to
circulate
through
the
radia-
tor,
the
temperature
switch
will
not
close
and
the
auxiliary
cooling
fan
will
not
run
.
Before
making
the
tests
described
be-
low,
make
sure
the
thermostat
is
operating
correctly
as
de-
scribed
earlier
.
The
normal
switching
temperatures
for
the

dual
-speed
switch
are
listed
in
Table
b
.

NOTE-

Some
cars
covered
by
this
manual
may
have
an
alter-
nate
cooling
fan
switchwith
switching
temperatures
of
176%190W
(80%88°C)
.
When
replacing
the
switch
check
theswitching
specifications,
whichshouldbe
stamped
on
the
switch
body
.

1
.
If
coolant
is
circulating
at
normal
operating
tempera-
ture,
but
auxiliary
cooling
fan
does
not
run,
disconnect
connector
from
radiator
temperature
switch
and
make
tests
listed
in
Table
c
.

Table
c
.
Auxiliary
Cooling
Fan
Temperature

Switch
Tests

Wires
jumpered



Test



Test
resuits
conditions

Black/green
(terminal2)
and



Ignition
ON



Fan
runs
on
brown
(terminal
1)



low
speed

Black/gray
(terminal
3)
and



Ignition
ON



Fan
runson
brown
(terminal



I
1)



high
speed
2
.
If
fan
runs
only
when
powered
directly
by
jumpered
connector
and
hot
coolant
is
circulating
through
radia-
tor,
radiator
temperature
switch
is
most
likelyfaulty
.
Use
a
new
sealing
ring
when
replacing
switch

Tightening
Torque

"
Temperature
switch
to
radiator
......
15
Nm
(11
ft-Ib)

3
.
If
auxiliary
fan
does
notrun
when
powered
directly,
check
for
battery
voltage
at
temperature
switch
connec-
tor
(black/green
wire)
with
ignition
on
.
If
battery
voltage
is
not
present,
check
fuses
.
See
610
Electrical
Com-
ponent
Locations
.

RADIATOR
AND
COOLING
SYSTEM



170-
5

~r~nmm
a
00
0

Fig
.
4
.



Auxiliary
radiator
cooling
fan
low
speed
relay
(1)
and
high
speed
relay
(2)
in
power
distribution
box
.
(Relay
locations
may
vary
.)

Auxiliary
Cooling
Fan
Circuit
Fuses



Fig
.
5
.
Auxiliary
radiator
fan
resistor
(arrow)
.
"
Fuse16
.
...................
..
..
...
...
.5
amp

"
Fuse
41
(ex
.
M44
w/man
.
trans)
.
..
.
..
.....
30
amp

"
Fuse
48
(M44
w/man
.
trans
.
only)
..
.
..
.....
40
amp



COOLING
SYSTEM
SERVICE

0013034

4
.
If
no
faults
are
found,
remove
low
speed
relay
and
turn



Coolant,draining
and
filling

ignition
ON
.
See
Fig
.
4
.



1
.
Remove
expansion
tank
cap
.
Set
temperature
controls
"
Check
for
power
at
terminal
30
and
terminal
86
of
relay



to
full
warm
.
socket
.

"
Reinstall
low
speed
relay
and
repeat
testat
high
speed



WARNING
-
relay
socket
.
Fix
any
wiring
faults
found
.



Allow
the
cooling
system
to
cool
before
openlng
or

On
early
productioncars
(up
to
9/92)
:
If
fan
operates
only
on



draining
the
cooling
system
.

high
speed
and
no
electrical
faults
have
been
foundup
to
this
point,
usean
ohmmeter
to
check
that
fan
resistor
is
not
electri-



2
.
Place
3
ra
allo

ug
.



beneath
radiator
drain
plug
and
re-

cally
open
.
Resistor
is
mounted
on
auxiliary
cooling
fan
housing



move
drain
plg
.
See
Fig
.
6
.

behind
front
grille
.
See
Fig
.
5
.
Wiring
diagrams
for
the
radiator

cooling
fan
canbefoundunder
Electrical
Wiring
Diagrams
.



3
.
Place
3-g



pail
beneath
rear
of
engine
blo
.
Loos-
en
and
re

mlon

ove
engine
blockcoolant
drain
plug
k
.

COOLING
SYSTEM
SERVICE

170-6



RADIATOR
AND
COOLING
SYSTEM

Fig
.
6
.



Radiator
drain
plug
(arrow)
.

WARNING
-

Coolant
is
poisonous
.
Itis
especially
lethal
to
pets
.

Cleanup
spills
immediately
and
rinse
the
area
with

water
.

NOTE
-

The
block
drain
plug
is
located
on
the
exhaust
side
of
the
engine,
near
the
reas
of
the
engine
.

4
.
Reinstall
radiator
and
engine
block
drain
plugsusing

new
sealing
washers
.
Leave
heater
controis
on
full

warm
.

5
.
Using
a
coolantmixture
of
50%
antifreeze
and
50%
dis-

tilled
water,
fill
system
slowly
On
radiator
with
integral

expansion
tank,
bleed
cooling
system
as
described
be-

low
.

NOTE-

"
Tap
water
may
cause
corrosion
of
radiator,
engine
and
coolant
hoses
.

"
Coolant
can
often
be
reused
provided
itis
clean
and
less
than
twoyears
old
.
Do
not
reuse
coolant
when
re-
placing
damaged
engine
parts
.
Contaminated
coolant
may
damage
the
engine
or
cooling
system
.

Tabled
.
Cooling
System
Capacities

Engine



j
Capacity

4-cylinder



1
6
.5
liters
(6.9
qt)

6-cylinder
M50/M52



10
liters
(10
.6
qt)
S50US/S52US



10
.5
liters
(11
.1
qt)

COOLING
SYSTEM
SERVICE

Tightehing
Torques

"
Radiator
drain
plug
to
radiator
...
2-3
Nm
(18-27
in-lb)

"
Engine
block
drain
plug
to
block



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

Cooling
system,
bleeding

(radiator
with
integral
expansion
tank)

NOTE
-

On
radiators
with
a
separate
expansion
tank,
ableed

screw
is
not
provided
.
The
cooling
system
with
sepa-

rate
expansion
tank
is
self
bleeding
via
the
vent
hose

on
the
expansion
tank
.

Air
maybecome
trapped
in
the
system
during
filling
.

Trapped
air
can
prevent
proper
coolant
circulation
.
Whenever

the
coolant
is
drained
and
filled,
the
system
should
be
bled
of

trapped
air
.

1
.
With
engine
cold,
add
coolant
to
expansion
tank
until

level
reaches
COLD
(KALT)
mark
on
tank
.

2
.
Loosen
bleed
screw
on
radiator
expansion
tank
.
See

Fig
.
7
.

0011976

Fig
.
7
.



Cooling
system
bleed
screwon
radiator
(arrow)
.
Note
cold
level
mark
on
expansion
tank
.

3
.
M3
models
:
Loosen
bleed
screw
on
thermostathous-

ing
.

4
.
Set
temperature
controls
in
passenger
compartment
to

fui¡
warm
and
turn
ignition
on
position
(do
not
start
en-

gine)
.

5
.
Slowly
add
coolant
until
it
spills
from
bleed
screws
.

When
coolant
spillíng
from
bleed
screws
is
free
of
air

bubbies,
tighten
screws
.

6
.
Run
engine
until
it
reaches
operatíng
temperature
.
Af-

ter
engine
has
cooled,
recheck
coolant
level
and
top
up
as
necessary
.

CAUTION-

Always
use
genuine
BMW
coolant
or
its
equiva-

lent
to
avoid
the
formation
of
harmful,
clogging
de-

posits
in
the
cooling
system
.
Use
of
other
antifreeze
solutions
may
be
harmful
to
the
cooling
system
.

Tightening
Torque

"
Radiator
bleed
screw

to
thermostat
housing
...
.
.
........
8
Nm
(71
in-lb)

Belt-driven
cooling
fan,
replacing

1
.
Usinga32
mm
wrench
on
fan
clutch
nut,
turn
wrench

quickly
in
a
clockwise
direction
(working
from
front
of

car)
to
loosen
.
Spin
fan
off
pump
.
See
Fig
.
8
.

NOTE-

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

"
The
nut
may
be
difficult
to
loosen
.
Use
a
tool
to
hold
the
coolant
pump
pulleystationary
.
BMW
hasa
spe-
cial
tool
forthis
purpose
(BMW
special
tool
no
.
115
030)
.

2
.
Remove
expansion
rivets
holding
shroud
to
radiator
.

See
Fig
.
9
.
Remove
fan
and
shroud
together
.

NOTE-

Store
the
removed
fan
clutch
assembly
in
an
upright
(installed)
positionto
prevent
lossof
clutch
fluid
.

RADIATOR
AND
COOLING
SYSTEM



170-
7

Fig
.
8
.



Radiatorcooling
fannut
(arrow)
.
Nuthas
left-hand
threads
.

3
.
To
replace
fan
clutch,
remove
fan
mounting
bolts
and

separate
clutch
from
fan
.
Fig
.
9
.



Fan
shroud
retaining
rivet
(arrow)
.
Pryout
center
pin
and
re

4
.
Installation
is
reverse
of
rernoval
.



move
rivet
.
Rivet
design
may
vary
depending
on
model
and

model
year
.

Tightening
Torques

"
Clutchnut
to
coolant
pump
(left-hand
threads)

Wíthout
BMW
tool
no
.
11
5
040
.....
40
Nm
(29
ft-lb)

With
BMW
tool
no
.
11
5
040
.
......
30
Nm
(22
ft-Ib)

"
Fan
to
viscous
clutch
...
.
..
.
......
10
Nm
(89
in-lb)

0013203

COOLING
SYSTEM
SERVICE

Fig
.
13
.
Version
2
auxiliary
fan
mounting
screws
(arrows)
.
Front
bumper
hasbeen
removed
.

4
.
Installation
is
reverse
of
removal
.

Thermostat,
replacing

0013146

The
coolant
thermostat
is
instalied
in
a
housing
at
the
front

of
the
cylinder
head
.
See
Fig
.
14
.

Fig
.
14
.
Coolantthermostat
and
housíng
.

NOTE-

On
M44
engines,
the
thermostat
is
integrated
into
the
thermostat
housíng
.
If
the
thermostat
requiresreplace-
ment,
the
complete
thermostathousing
mustbe
replaced
.

RADIATOR
AND
COOLING
SYSTEM



170-
9

WARNING
-

Allow
the
cooling
system
to
cool
before
opening
ordraining
the
system
.

2
.
Remove
belt-driven
cooling
fan
and
fan
shroudas
de-

scribed
earlier
.

3
.
On
M52/S52US
engines
:
Unclip
wiring
duct
retaining
clips
and
remove
duct
from
above
thermostat
housing
.

Also
remove
engine
front
lifting
bracket
.

4
.
Remove
thermostat
housing
from
front
of
engine
.
See
Fig
.
15
.

Fig
.
15
.
Thermostat
housíng
shown
removed
(6-cylinder
engine)
.

NOTE-

Some
thermostats
have
a
direction
arrowor
venthole
near
the
edge
.
Install
the
thermostat
so
that
either
the
arrow
or
hole
are
at
thetop
.

CAUTION
-

Be
sure
to
reconnect
ground
wire(s)
at
thermostat
housing
mounting
bolt,
where
applicable
.

5
.
Remove
thermostat
.
Note
thermostat
direction
and
ori-

entation
before
removing
.

6
.
Insta¡¡
new
thermostat
and/or
thermostat
housing
using

new
O-ring
and
gasket(s)
as
necessary
.

oo131ss



7
.
Installation
is
reverseof
removal
.
Fill
system
with
cool-

ant
as
described
under
Coolant,draining
and
filling
.

Tightening
Torques

1
.
Drain
radiator
as
described
above
under
Coolant,



"
Thermostat
housing
cover

draining
and
filling
.



to
housing
orcoolant
pump
..
..
....
10
Nm
(89
in-lb)

"
Engine
lifting
bracket
bolt
to
thermostat
housing

(M52/S52US
engine)(M8)
....
..
...
22
Nm
(17
ft-Ib)

COOLING
SYSTEM
SERVICE

Fig
.
19
.
Coolant
pump
being
removed
.
Thread
two
M6
bolts
(arrows)
in
evenly
to
withdraw
pump
.
(Thermostat
and
hoseshavebeen
removed
tor
visual
access
.)

8
.
Installation
is
reverse
of
removal
.

"
Be
sure
to
replace
O-ring
and
gaskets
.

"
Coat
O-ring
with
lubricant
during
installation
.

Tightening
Torque

"
Coolant
pump
to
timing
chaincover

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

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

"
Coolant
pump
pulley

to
coolant
pump
.................
10
Nm
(89
in-lb)

RADIATOR
SERVICE

Radiator,
removing
and
installing

1
.
Drain
radiator
as
described
earlier
.

WARNING
-

Allow
cooling
system
to
cool
before
opening
ordraining
system
.

2
.
Remove
primary
cooling
fan
(belt-driven
or
electric)
as

described
earlier
.

3
.
Disconnect
coolingfan
and
leve¡
sensor
harness
con-

nectors
from
bottom
of
radiator,
where
applicable

4
.
Disconnect
harness
connector
from
auxiliary
fandual

temperature
switch
.
See
Fig
.
20
.

5
.
Disconnect
all
coolant
hoses
from
radiator
.

RADIATOR
AND
COOLING
SYSTEM



170-11

0012500

Fig
.
20
.
Cooling
fan
dual
temperatura
switch
(arrow)
on
right
sido
of
radiator
.

6
.
Where
applicable,
disconnectautomatic
transmission
fluid
(ATF)
cooler
lines
from
radiator
.
See
Fig
.
21
.

Fig
.
21
.
Automatic
transmission
fluid
(ATF)
linos
at
radiator
.

7
.
Carefully
pryout
radiator
retaining
clips
from
top
of
ra-

diator
.
See
Fig
.
22
.

8
.
Pul¡
radiator
up
and
out
of
car
.

NOTE-

The
radiator
rests
ontwo
rubber
mounts
.
Check
that

the
mounts
do
not
stick
to
the
bottomof
the
radiator
.

RADIATOR
SERVICE

180-
4



EXHAUST
SYSTEM

Fig
.
6
.



Exhaust
system
support
bracket
on
6-cylinder
engine
.
Re-
move
bolts
(arrows)
to
separate
from
exhaust
pipe
.

Fig
.
7
.



Rubber
exhaust
system
hangers
.
Remove
hanger
by
prying
off
bracket
(arrows)
.

EXHAUST
SYSTEM
REPLACEMENT

7
.
Installation
is
reverse
of
removal
.

"
Where
necessary,
transfer
parts
from
old
system
to
re-
placement
system
.

"
Coat
manifold
studs
with
copper
paste
before
installing

nuts
.

"
Where
applicable,
tighten
front
pípewith
semi-flexible

compensator
last
when
installing
front
pipe
to
mani-

folds
.

"
Make
sure
there
is
at
least
20
mm
(
3
/4
in
.)
of
clearance

between
exhaust
systemand
car
body
at
every
point
.
"
Loosely
install
all
exhaust
system
mountinghardware
and
hangers
before
tightening
fasteners
to
their
final
torque
.

"
On
4-cylinder
engines
:
Tighten
center
mounting
flange
nuts
evenly
until
correct
dimension
is
obtained
.
See

Fig
.
8
.

ri

J%JJ

w

~~~JJJJ

1

Fig
.
8
.



On
4-cylinder
engines,
tighten
nuts
evenly
so
that
spríngs
are
preloaded
to
Dimension
A
.

NOTE-

To
prevent
exhaust
system
rattles
and
vibration,
pre-load
the
rear
clamping
brackets
in
the
íonaard
direction
.
See
Fig
.
9
.

0011937

Tightening
Torques

"
Cross
brace
to
chassis



..
.
...
.
..
..
21
Nm
(17
ft-Ib)

"
Exhaust
support
bracket

to
transmission
.
.
.
.
.......
.....,.
21
Nm
(17
ft-Ib)
"
Exhaust
system
mounting
clamps
...
15
Nm
(11
ft-Ib)

"
Front
exhaust
pipeto
exhaust
manifold
M10
nut
.
.
.
...
.
..
..............
30
Nm
(22
ft-Ib)

"
Front
exhaust
pipe
torear
pipe

M8
bolt/nut
..
....
.
..............
22
Nm
(16
ft-Ib)
with
compression
spring
................
See
Fig
.
8
"
Oxygen
sensor
to
exhaust
pipe
.....
55
Nm
(41
ft-Ib)