Honda Bmw 5 Service Manual
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110-19 Engine Removal and Installation M62 engine, remove ASC throttle body. Disconnect electrical harness from throttle position sensor. - Disconnect ASC actuator cable (arrow). . Remove mounting fasteners and remove throttle body. On front of left side cylinder head, disconnect electrical har- ness connector (A), and remove and plug fuel tank vent valve vacuum line (0). Raise car and support in a safe manner. CAUTION- Male sure the car is stable and well supported at aN times. Use a professional automotive lifi orjackstands designed for I the ouroose. A floor jack is not adequate support. Working beneath car: - Remove engine splash shield. Remove right and left heat shield from front suspension subframe. Working underneath engine compartment, disconnect ground cable on right side engine mount (arrow).
11 0-20 Engine Removal and Installation Working at right side of transmission bellhousing, disconnect electrical harness connections (arrows) from starter. Re- move starter retaining bolts and remove starter from trans- mission mount. M62 TU engine: Disconnect electrical harness connector for right oxygen sensor from retaining clip and remove re- taining clip from transmission. - Working underneath engine compartment at left side: Unclip positive battery cable from oil pan. . Remove alternator cooling duct. 4 M62 engine: Remove fastener A and plug connector B from alternator. - M62 TU engine: Remove electrical harness connectors from front of water cooled alternator. - Remove exhaust system and transmission. See 180 Ex- haust System and 230 Manual Transmission or 240 Auto- matic Transmission. - Working at front of engine: Remove upper and lower hoses from radiator. D~sconnect expansion tank hose from coolant pump. - Remove belt-driven cooling fan: Counterhold fan with special tool 11 5 050. Turn fan mounting nut (32 mm) clockwise (left hand threads) to loosen. Rotate fan clockwise to remove. Remove cooling fan shroud: Disconnect electrical connectors from coolant level sensor (B) and coolant temperature sensor (C). . Remove expansion rivets (A) from each side of shroud Remove coolant hose (D). Slide fan shroud with expansion tank up. Remove radiator overflow tube from spout of expansion tank. Remove radi- ator fan shroud with expansion tank. Remove radiator. See 170 Radiator and Cooling System.
-- -- Engine Removal and installation - Remove polyribbed A/C compressor belt: Mark direction of belt travel if belts are to be reused. Loosen bolts (A). Turn adjusting lug (B) clocltwise to release belt tension. Working beneath car, remove power steering pump and air conditioner compressor. Suspend from body using stiff wire. Remove exhaust manifolds. See 180 Exhaust System. < lnstall engine lifting device (BMW 11 0 000 or equivalent) to front and rear engine supports and raise engine until its weight is supported. Detach engine mounts. a Watch carefully for hoses and electrical wires that might snag. - installation is reverse of removal: Replace all gaskets, O-rings and seals. V-8 engine mounts have two sets of mounting holes. E39 cars use front most mounting holes. * On cars with automatic transmission, use new O-rings at ATF cooler lines. Use new alignment sleeves when installing transmission. Be sure engine drive belts properly engage pulley grooves. When installing belt, preload tensioner to stop (toward belt), then tighten tensioner clamping nut. lnstall front exhaust pipes using new gasltets and copper paste and new mounting hardware. See 180 Exhaust System. Change engine oil and filter. Check all other fluid levels as described in 020 Maintenance. Refill and bleed cooling system as described in 170 Radi- ator and Cooling System. CAUTION- Do not interchange knoclc sensor harness connectors. Seri- ous engine damage may result
Engine Removal and Installation Tightening torques ATF cooler lines to radiator (use new O-rings) MI8 cap nut 20 Nm (15 ft-lb) M22 cap nut 22 Nm (17 ft-lb Coolant drain plug to cylinder blocic (M14) 25 Nm (18 ft-lb) Engine mount to engine bracket or 47 Nm (35 ft-lb) subframe (M10) Exhaust flange nuts (8 mm) 25 Nm (18 ff-ib) Radiator cooling fan to coolant pump 40 Nm (30 ft-lb) (left-hand threads) Radiator drain screw to radiator 2.5 Nm (22 in-lb) Wirino to alternator (ME nut) 13 Nm (9.5 ft-lb)
113-1 11 3 Cylinder Head Removal and Installation General ........................... .I 13-2 Special tools ........................ .I 13-2 Diagnostic Testing. ................ .I1 3-5 Cylinder compression, checking ......... ,113-5 Wet compression test ................. .I1 3-7 Cylinder leak-down test. ................ 11 3-8 Cylinder Head Removal and Installation (M52 Engine) ...................... .I1 3-8 Cylinder head, removing, M52 engine .... ,113-8 Cylinder head, installing, M52 engine ... ,113-17 Cylinder Head Removal and Installation (M52 TU and M54 Engines). ........ ,113-22 Cylinder head, removing, M52 TU and M54 engines. ................... .I1 3-22 Cylinder head, installing, M52 TU and M54 engine. .................... .I1 3-39 Double VANOS Timing Chain Components ................ 11 3-46 Double VANOS timing chain components, installing, M52 TU and M54 engines ..... 113-46 Cylinder Head Removal and Installation (M62 Engine). ..................... 11 3-56 Intake manifold, removal and installation, M62 engine. ........................ 11 3-66 Left cylinder head, removing, M62 engine. ........................ 11 3-61 Left cylinder head, installing, M62 engine. ........................ 11 3-66 Right cylinder head, removing, M62 engine ........................ 11 3-72 Right cylinder head, installing, M62 engine ........................ 11 3-77
11 3-2 Cylinder Head Removal and Installation This group covers cylinder head removal and installation as well as cylinder headlvalve diagnostic procedures. In the procedures in this repair group, engines are referred to by engine code. If necessary, see 100 Engine-General for engine code and application information. The information given in this repair group assumes that the engine is installed in the engine bay. On the 6-cylinder en- gines, the VANOS control unit must be removed in orderto re- move the cylinder head from the engine block. On M52TU and M54 engines, camshafts must be removed from the cylin- der head before the head is removed. The cylinder head removal and installation procedures for the M62 V-8 are also included, butthe proceduresforthe M62TU V-8 with VANOS are not provided. For cylinder head and valvetrain reconditioning information, see 116 Cylinder Head and Valvetrain. For specific repair procedures, refer to the appropriate repair group: 020 Maintenance 116 Cylinder Head and Valvetrain 117 Camshaft Timing Chain 170 Radiator and Cooling System 610 Component locations NOTE- If a head gasket problem is suspected, a compression test or leak-down test will usually detect the fault See Diagnostic Testing later in this group. Special tools Special BMW service tools are required to properly remove and install the cylinder head on engines covered by this man- ual. The special tools are used to time the valvetrain to the crankshaft, and to remove the VANOS control unit, the cam- shafts and the Tom (El2) head bolts. Read the entire proce- dure through before beginning the job.
11 3-3 Cylinder Head Removal and Installation 4 Rotary angle torque dial gauge (Tool No. BMW 11 2 250100 9 120) 4 El2 Torx socket for cylinder head bolts (Tool No. BMW 11 2 250) 4 Crankshaft loclting tool (Tool No. BMW 11 2 300) 4 Camshaft locking tool set, 6-cylinder /I (Tool No, BMW 11 3 240) < Timing chain adjustable tension setup tool, 6-cylinder (Tool No. BMW 11 4 220) > Double VANOS adiustment date 4 Secondary sprocket setup tool for double VANOS (Tool No. BMW 11 6 180)
11 3-4 Cylinder Head Removal and Installation 4 Camshaft locking tools (cyl. 5-8), V-8 112442 112446 (Tool No. BMW 11 2 44211 1 2 44611 1 2 44311 1 2 444) 4 Camshaft loclting tools (cyl. 1-4), V-8 (Tool No. BMW 11 2 44511 1 2 44111 1 2 44311 1 2 444) 4 Timing chain adjustable tension setup tool, V-8 (Tool No. BMW 11 3 390) Secondary timing chain tensioner loclting pin, V-8 (Tool No. BMW 11 3 310) 4 Hydraulic lifter securing plugs (Tool No. BMW 11 3 250) < Camshaft bearing cap tensioner (6-cylinder) for camshaft removal and installation (Tool No. BMW 11 3 26011 1 3 270) 4 Secondary timing chain tensioner loclt set (Tool No. BMW 11 3 29111 1 3 292)
113-5 Cylinder Head Removal and Installation I < Fuel line plugs (Tool No. BMW 13 5 281113 5 282) 4 Fuel line removal tool for quick-disconnect fittings (Tool No. BMW 16 1 050) < Tensioning bracket (V-8) (Tool No. BMW 11 7 380) Compressed air fitting for testing VANOS operation ((Tool No. BMW 11 3 450) < Upper timing cover installation tool set, V-8 (Tool No. BMW 11 1 41 0) Cylinder compression, checking A compression gauge is needed to make a compression test. For accurate test, the battery and starter must be capable of cranking the engine at least 300 rpm, and the engine should be at normal operating temperature. NOTE- Performing a compression test may cause a fault to set in the ECM and may illuminate the Malfunction Indicator Light (MIL). The light can only be turned out using either BMW special service scan tools or an equivalent aftermarket scan tool. Disconnecting the battery will not erase the fault memo- ry or turn out the light. See OBD On-Board Diagnostics.
11 3-6 Cylinder Head Removal and Installation - Disable ignition system by removing DME main relay. See 610 Component Locations for relay location. WARNING- . The ignition system produces high voltages that can be fa- tal. Avoid contact with exposed terminals and use exfreme caution when working on a car with the ignition switched on or the engine running. Do not touch or disconnect ignition components while the engine is running or being cranked by the starter. Failure to remove the DME main relay or attempting to disa- bie the fuel andignition systems by other methods may result in damaoe to the enoine control module (ECM). - - Remove plastic cylinder head cover(s) ,,I . ,. .*,.,,&- - Remove coil grounding straps. I CAUTION- I nition system components. I - Remove coils. - Remove spark plugs from all cylinders. NOTE- Check the spark plugs for oil deposits that may indicate poor cylinder sealing, then set them aside in order. Used spark plugs should be reinstalled in the same cylinder from which they were removed. 4 Install compression gauge in first cylinder spark plug hole, tight enough to form a good seal. - With parking brake set, transmission in PARK or NEUTRAL, and accelerator pedal pressed to floor, crank engine with starter. Record highest value indicated by gauge. NOTE- * The compression gauge reading should increase with each compression stroke and reach near its maximum reading in about 4-6 strokes. All cylinders should reach maximum compression in the same number of strolces. If a cylinder needs significantly more strokes to reach maximum compression, there is a problem.