Honda Bmw 5 Service Manual

- Raise and safely  support  vehicle 
WARNING- 
Make sure the car  is stable  and well supporied at all times. 
Use a professional  automotive /iff orjack stands designed for 
the 
ournose. A floor jack is  not  adeouate suooort. 
- If necessary, remove transmission  splash shield. 
- Disconnect fluid  line from slave cylinder  on lefl  side  of trans- 
mission.  Place  pan under hose to catch dripping fluid. 
4 Working underneath transmission,  remove slave cylinder 
mounting  nuts (arrow)  from clutch...

21 0-1 0 
Clutch 
Installing the non-SAC clutch (1 997 5281 model) requires  the 
use  of only  a flywheel lock and traditional  clutch disc align- 
ment tool. 
Installing  the self-adjusting  clutch (SAC) requires several 
special tools  for aligning  and assembling  the clutch,  as well  as 
locking  the flywheel  in place.  In addition,  the procedure for  re- 
installing  a previously used SAC differs from  the procedure 
for installing 
a new  SAC.  Be sure  to read  the SAC installation 
procedure...

Clutch, removing 
The procedure  given here  applies to both non-SAC  and SAC 
clutch  assemblies. 
- Remove transmission  from  engine. See 230 Manual Trans- 
mission. 
4 Loosen 6 clutch mounting  bolts (arrows)  evenly 
- Remove pressure  plate and clutch disc. 
WARNING- 
The clutch disc contains  asbestos. Inhaling or ingesting as- 
bestos dust can cause  severe health problems.  Always wear 
an  approved respiratorandprotective clothing  when handling 
components containing  asbestos. Do not use...

21 0-1 2 
Clutch 
Release bearing 
Release 
bearin 
- lnspect  flywheel for  scoring,  hot spots, cracks or loose or 
worn  guide  pins. If any  faults  are found, replace flywheel  as 
described  later. 
- lnspect transmission  pilot  bearing in end of crankshaft.  The 
bearing should  rotate smoothly without  play. If necessary, 
replace as  described later. 
4 lnspect and clean  release  bearing  lever. Apply a thin coat of 
grease to  release  bearing lever lubrication points  (arrows). 
Clean  and...

Checlc flywheel  location dowel 
and  correct  installation.  sleeve (arrow) for 
damage 
4 When  installing dual-mass  flywheel, position dowel  sleeve 
next  to two  locating notches 
(arrows). 
- Install flywheel using  new self-locking bolts, 
Tightening torque  Flywheel  to cranltshaft 
(use  new self-locking  bolts) 
120 Nm (89 ft-lb) 
Use new self-lock~ng bolls lo rnslall llylvheel Do not reuse llle 
old slrelch-lype bolls  Do  nor rnsrall bolls wrlh Loct~lo@ or srm- 
I ilar thread licking...

210-1 4 
1 Clutch 
Dowel sleeve I 
Check flywheel  location 
and  correct  installation.  dowel sleeve 
(arrow) 
for . damage 
< When  installing  dual-rnass flywheel,  position dowel sleeve 
next  to two  locating  notches (arrows). 
- Lightly oil flywheel  mounting bolt threads  and torque to 
specification. 
Tightening torque 
Flywheel to  crankshaft 105 Nm (77 ft-lb) 
CAUTIOI\C 
Do not  reinstall flywheel bolls  with LoctiteCTJ or similar thread 
locl~ing compound. 
- Install transm~ssion as...

21 0-1 5 
Clutch 
Use crankshaft pulley bolt to  rotate engine  in direction  of ro- 
tation until  a full  pulse tooth 
(arrow) is centered  in pulse sen- 
sor opening. 
Measure depth  from pulse sensor  mounting surface on trans- 
mission  to top  of tooth. 
Q Measure length (A) of pulse sensor from mounting surface to 
end. 
- Subtract length  of pulse sensor (A) from distance to pulse 
tooth  from mounting  area on transmission.  This resulting 
measurement  is  the pulse sensor air  gap. Use shims...

21 0-1 6 
Clutch 
4 Press new bearing into place using  BMW special tool 
11 2 350 or  equivalent  driver. 
Clutch, installing (non-SAC) 
CAUTIOG 
Avoidcontaminating clutch  friction surfaces  with oilorgrease. 
Do not  touch these surfaces. 
4 Center clutch  disc on flywheel using centering tool 
Clutch Clutch pressure disc plate 
Dual mass flywheel - 
5-speed  transmission:  Special tool 21 2 130 
- Install flywheel lock, BMW special tool 11 2 170. 
4 Install pressure plate and clutch  disc to...

Clutch 
- Remove flywheel locking tool 
4 Inspect and clean release bearing  lever. Apply  a thin coat of 
grease to  release bearing  lever lubrication points. Install re- 
lease bearing. Bearing  tabs 
(A) align with contact points (B) 
on release  lever. 
CAUTION- 
Do not grease  release  bearing guide sleeve.  If guide  sleeve 
is  greased,  release bearing  may stick  to it. 
- Clean and lightly lubricate clutch  disc splines  and transmis- 
sion input shaft  splines. 
- Install transmission. See...

21 0-1 8 
Clutch 
- lnstall flywheel lock, special tool 11 2 170 (6 cylinder model) 
or 
11 2 070 (V-8 model). 
- Install  SAC pressure plate on  dowel pins at flywheel.  lnstall 
clutch mounting  bolts and tighten each one  turn at a time  until 
pressure plate  is fully seated. Torque to specification. 
Tightening torques  Clutch  to flywheel 
- M8 (8.8  grade) 
MB 110.9 orade) 
24 Nm (1 8 it-lb) 
34  Nm  (25 
ft-lb) 
Use 14 mm  Allen wrench to  unscrew (clocltwise or counter- 
clockwise)  lock plate...