Honda Bmw 5 Service Manual
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Battery, Starter, ~lternatorl Alternator, removing and installing (6-cylinder engine) A replacement alternator should have the same rating as the original. Alternator manufacturer and ampere rating are nor- mally marked on the alternator housing. - Disconnect negative (-) battery cable. CAUTION- Prior to disconnecting the batteg read the battery discon- nection cautions given in 001 General Warnings and Cau- I tions. Remove complete air filter housing: Loosen intake duct hose clamp (A) at throttle assembly. Loosen clamp and remove idle control hose from intake duct (B) and disconnect idle speed control valve electrical harness connector. Disconnect electrical harness connector (C) from mass air flow sensor. * Remove air filter housing mounting screw (D), Disconnect vent tube (E). Loosen air intake duct clamp (F). Carefully lifl air filter housing out of engine bay. Remove alternator drive belt. See belt removal procedures in 020 Maintenance. - Remove radiator cooling fan and fan shroud. See 170 Radi- ator and Cooling System. NOTE- The radiator cooling fan nut (32 mm wrench) has left-hand threads. - Unbolt power steering fluid reservoir and bracket. Suspend to one side without detaching fluid hoses. - Disconnect alternator air cooling tube. - Disconnect wiring from rear of alternator. 4 Remove upper and lower mounting bolts (arrows) and lift alternator. If idler pulley for belt interferes, remove pulley cover and retaining bolt to remove pulley. out
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121-16 Battery, Starter, Alternator - installation is reverse of removal. Tightening torques Belt tensloner to engine block M8 (8.8 grade) 22 Nm (16 ft-ib) Fan clutch to coolant pump with BMW special tool 11 5 040 30 Nm (22 ft-lb) without BMW special tool 11 5 040 40 Nm (29 ft-ib) Pulley to alternator 70 Nm (44 ft-lb) Terminal 30 (B+) wire to alternator (M8) 13 Nm (10 ft-ib) Alternator, removing and installing (M62 engine, air cooled) A replacement alternator should have the same rating as the original. Alternator manufacturer and ampere rating are nor- mally marked on the alternator housing. - Disconnect negative (-) battery cable. CAUTION- Prior to disconnecting the battery, read the battery discon- nection cautions 001 General Warnings and Cautions. - Remove cooling fan and alternator drive belt. See 020 Main- tenance. - Pry out trim caps and remove fasteners from plastic cover on left head. Lift off cover. Disconnect positive (+) lead from jump start post (arrow). Raise car and support in a safe manner. WARNING- Make sure the car is stable and well supported at aN times. Use a professional automotive lift orjack stands designed for the purpose. A floorjack is not adequate support.
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121-17 Bauery, Starter, Alternator - Remove engine splash shield from underneath car. Working underneath car at rear of alternator, loosen alterna- tor air cooling duct clamp (arrow) and remove duct. Remove three alternator mounting fasteners (arrows) Pull alternator forward and disconnect wiring from rear of alternator. Release clip retaining wiring harness to alternator. Rotate alternator forward and then up and out of engine com- partment, using care to not damage radiator. CAUTIOe Protect radiator with heavy cardboard or sheet metal. Installation is reverse of removal, Tightening torques Fan clutch to coolant pump with BMW special tool 11 5 040 30 Nm (22 ft-lb) without BMW special tool 11 5 040 40 Nm (29 ft-lb) Pullev to alternator 70 Nm 144 it-lb) -, Terminal 30 (Bt) wire to alternator (ME) 13 Nm 110 ft-lb
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121-18 I Battery, Starter, Alternator Alternator, removing and installing (M62 TU engine, water cooled) V-8 models produced after 9/98 are equipped with a water cooled alternator. CAUTION- Allow engine to cool before removing alternator as coolant will escape from the alternator water jacket. - Disconnect negative (-) battery cable CAUTION- Prior to disconnecting the battew read the battery discon- nection cautions given in 001 General Warnings and Cau- tions. - Remove radiator cooling fan and fan shroud. See 170 Radi- ator and Cooling System. - Drain engine cooling system. See 170 Radiator and Cool- ing System. - Remove alternator drive belt. See 020 Maintenance. - Disconnect battery lead (terminal 30 or B+) and two-pin har- ness connector from front of alternator. I < Remove bolts securing alternator to water jacket and remove aling ring alternator. NOTE- If necessary, raise car and remove engine compartment splash shield to access lower alternator mounting bolts. The upper coolant hose can also be removed to assist al- ternator removal.
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Battery, Starter, Alternator - Installation is reverse of removal, noting the following: Replace alternator rubber sealing O-ring. * Fill and bleed cooling system as described in 170 Radiator and Cooling System. Tightening torques Fan clutch to coolant pump with BMW special tool 11 5 040 30 Nm (22 ft-lb) without BMW special tool 11 5 040 40 Nm (29 ft-lb) Terminal 30 (Bc) wire to alternator (ME) 13 Nm (10 ft-lb) STARTER Starter troubleshooting Typical starter wiring terminal identification is shown. Large wire at terminal 30 (not shown in photo) is direct battery volt- age. Smaller wire at terminal 50 operates starter solenoid via ignition switch. If starter turns engine slowly when ignition is in start position: Check battery state of charge. Inspect starter wires, terminals, and ground connectlons for good contact. In particular, make sure ground connec- tions between battery, body and englne are completely clean and tight. If no faults are found, starter may be faulty and should be replaced. - If starter fails to operate, check EWS (drive-away protection system). Try another ignition key. If no faults can be found, have the EWS system checked using BMW scan tool equip- ment. Checkclutch pedal operated starter lock-out switch or gear position switch (automatic). NOTE- * A factory-installed drive-away protection system, also re- ferred to as EWS, is used on E39 cars. This system pre- vents operation of the starter if a specially coded ignition key is not used. On cars with automatic transmission, the transmission gear position switch signals EWS to prevent the engine from starting in gear positions other than PARK or NEU- TRAL. On cars with manual transmissions, a starter immobiliza- tion switch at the clutch pedal is used to prevent the starter from operating unless the clutch pedal is pushed fully to the floor.
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I Battery, Starter, Alternator - Check for battery voltage at terminal 50 of starter motor with key in start position. If voltage is not present, check wiring be- tween ignition switch and starter terminal. Check the EWS system and other inputs that disrupt terminal 56 to the start- er. See ELE Electrical Wiring Diagrams. If voltage is present and no other visible wiring faults can be found, prob- lem is most likely in starter motor. Starter, removing and installing (6-cylinder engine) The starter is removed from below. Access to starter bolts is difficult. Be sure to have the proper tools on hand before pro- ceeding. NOTE- Access to the starter wiring is very limited. Forbetteraccess, it may be necessary to remove the intake manifold. - Disconnect negative (-) battery cable. CAUTIOI\C Prior to disconnecting the battern read the baltery discon- nection cautions in OOlGeneral Cautions and Warnings. Remove complete air filter hous~ng: Loosen intake duct hose clamp (A) at throttle assembly. Loosen clamp and remove idle control hose from intake duct (B) and disconnect idle speed control valve electrical harness connector. Disconnect electrical harness connector (C) from mass air flow sensor. Remove air filter housing mounting screw (D) Disconnect vent tube (E). Loosen air intake duct clamp (F). Carefully lift air filter housing out of engine bay. Disconnect throttle cable. Raise vehicle and support safely. WARNING- Make sure the car is stable and well supported at all times. Use a professional automotive lift orjack stands designed for the purpose. A floorjaclc is not adequate support - Working underneath car, remove engine splash shield - Disconnect fuel lines and harness connectors from retaining brackets, as necessary.
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Battery, Starter, ~lternatorl - Disconnect wiring from starter. 4 Note routing for cables. Routing varies depending on model and transmission. When reinstalling, make sure cables do not chafe. - Using a long extension and universal joint from output end of transmission, remove bolts fastening starter to transmission bell housing and engine block. - Remove starter from below 4 Checlc starter pinion gear and flywheel teeth for damage. - Installation is reverse of removal. Tightening torques Starter to engine 47 Nrn (35 It-lb) Starter sipport bracket to starter 5 Nrn (44 in-lb) Starter support bracket to engine 47 Nrn (35 ft-lb) Wlre terminals to slarter M5 5 Nrn (44 in-lb) M6 7 Nrn (62 in-lb) M8 13 Nrn (10 ft-lb) Starter, removing and installing (V-8 engine) The starter is on the right (passenger) side of the engine, and is removed from below. Access to starter bolts is difficult. Be sure to have the proper tools on hand before proceeding. - Disconnect negative (-) battery cable CA UTIOW- Prior to disconnecting the battery, read the battev discon- nection cautions in OOlGeneral Cautions and Warnings. - - Raise vehicle and support safely. / WARNING- 1 ~ ~~ ~~ ~~~ ~ Make sure the car is stable and well supported at all times. Use a professional automotive lift orjacltstands designed for I the purpose. A floor jack is not adequate support I
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- Battery, Starter, Alternator - Working underneath car, remove engine splash shield. - Remove heat shield from starter. Remove starter wire mounting nuts (arrows). Disconnect wires from starter terminals and retaining clip. Disconnect main positive cable and bracket from suspen- sion. If necessary for access, remove right side oxygen sensor harness connector from retaining clip. Working from end of transmission, use suitable extensions and universal joint to remove starter mounting bolts (arrows) at transmission bellhousing. - Remove starter from below. - Check starter pinion gear and flywheel teeth for damage. - Installation is reverse of removal Tightening torques Starter to engine 47 Nrn (35 ft-lb) Wire terminals to starter M5 5 Nrn (44 in-ib) M6 7 Nm (62 in-ib) ME 13 Nrn (10 ft-lb)
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121-23 Battery, Starter, ~lternatorl Solenoid switch, removing and installing - Remove starter as described previously. - Disconnect field winding strap between starter motor and solenoid switch. NOTE- If the field winding strap is damaged or burned, a new or rebuilt starter motor is needed. < Remove solenoid switch mounting screws (arrows), and separate solenoid from starter. Unhoolc solenoid plunger from lever in starter drive - Installation is reverse of removal. Lubricate solenoid piston with light grease. CAUTION- When installing field winding strap to starter, position itso that it does not contact the starter body. Tightening torque Field strap to starter 13 Nm (10 ff-lb)