Honda Bmw 5 Service Manual
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Fuel Tank and Fuel pump/ - Remove suction hose from tank filler neck carefully to avoid damaging filler neck baffle plate. CAUTION- After finishing repairs but before starling engine, be sure there is at least 5 liters (1.5 gallons) of fuel in tanlc. The fuel pump will be damaged if run without fuel. Fuel tank, removing and installing - Remove fuel tank filler cap and drain tank as described earlier. - Disconnect negative cable from battery. CAUTION- Prior to disconnecting the battea read the battery discon- nection cautions given in 001 General Cautions and Warnings. - Remove rear seat bottom cushion. Peel forward lip of carpet from beneath seat cushion and carefully peel back insulation to expose fuel tank access cover on left and right sides. Re- move covers. Disconnect right side supply hose and electr~cal harness connector (arrows). D~sconnect left side return hose and electrical harness connector. Working inside car, disconnect parking bralte cable ends from parking brake lever. See 340 Brakes. Lift car and support safely. Make sure the car is stable and we/ supported at all times. Use a professional automotive lift orjack stands designed for the purpose. A floorjaclc is not adequate support. - Remove complete exhaust system and heat shield. See 180 Exhaust System. - Remove drive shaft. See 260 Driveshaft
160-22 Fuel Tank and Fuel Pump 4 Working underneath car, pinch off supply and return fuel hos- es (arrows), then disconnect hoses from rigid metal lines. - Remove right rear wheel and wheel housing splash shield. 4 Worlting at right rear wheel housing, loosen hose clamp (arrow) and disconnect filler pipe from tank. - Support tank from below. Remove tank strap mounting bolts. Lower and remove tank, disconnecting right side vent and other hoses/electrical connectors as necessary. Always use new seals, gaskets, O-rings, and hose clamps. lnspect hoses and replace any that are chafed, dr~ed out or cracked. lnspect heat shield and replace if corroded. Inspect rubber buffers and hers on fuel tank, support straps and on underside of body. Replace rubber parts that are hardened or damaged. - After finishing repairs but before starting engine, fill fuel tank with at least 5 liters (1.5 gallons) of fuel. CAUTlOI+ The fuelpump will be damaged if run without fuel. * If the filler neck has been removed from the body, be sure to reattach the neck grounding screw (where ap- plicable). Check electrical resistance between the ground tab and wheel hub. The resistance should be no hiaher than 0.6f2 Tightening torques Fuel tank to body 23 Nm (17 ft-lb) Hose clamp 8 -13 mm dia. 2 Nm (18 in-lb) Hose clamp 13 - 16 mm dia. 3 Nm (27 in-lb) Hose clamp 42 - 48 mm dia. 4 Nm (36 in-lb)
.- Fuel Tank and Fuel pump( - Fuel expansion tank, removing and installing - Raise rear end of car and support safely. CA U TIOG Make sure the car is stable and well supported at all times. Use a professional automotive lift orjack stands designed for the ouroose. A floor iack is not adequate support - Remove left rear wheel and wheel housing inner shield. 4 Remove plastic nut (A) and disconnect hose (B). 4 Tilt vent tank down and loosen or cut off hose clamps (arrows). Pull hoses off fittings. - Release vacuum line loclting clips and remove tank - Installation is reverse of removal. Use new hose clamps. Tightening torques Hose clamp 8 - 13 mm dia. 2 Nrn (18 in-lb) Hose clamp 13 - 16 mm dia. 3 Nm (27 in-lb) Hose clamp 42 - 48 mm dia. 4 Nm (36 in-lb)
Fuel Tank and Fuel Pump 1 Activated carbon canister I fuel tank leak detection unit (LDP or DMTL), removing . . - and installing - Raise rear end of car and support safely. CAUTION- Make sure the car is stable and well supported at all times. Use a professional automotive lift orjack stands designed for the purpose. A floor jack is not adequate support. - Remove left rear wheel and inner fender panel Remove carbon canisterlfuel tank leak detection unit (V-8 model shown): Disconnect electrical harness connector (A) from fuel tank leak detection unit. Pinch and remove quick-disconnect fittings at intake line to air filter housing (5) and hose to expansion tank (C). * Remove mounting clamp and lower canister with fuel tank leak detection unit. Installation is reverse of removal. Tightening torques Hose clamp 8 - 13 mm dia. 2 Nrn (18 in-lb) Hose clamp 13 - 16 rnm dia 3 Nm (27 in-lb) Running losses (312-way) valve, removing and installing The running losses (312-way) valve is located under the car beneath the drivers seat, just ahead of the fuel filter. A protec- tive covershieldsfuel system components from road hazards and dirt. The engine control module (ECM) controls the operation of the 312-way valve (pulse-width modulated). On engine start up, the valve solenoid is energized for 20 seconds in order to supply full fuel volume to the fuel rail. After20 seconds, the solenoid is deactivated and sprung closed (the bypass is opened). This reduces the amount of fuel circulating through the fuel rail and diverts the excess to return to the fuel tank through the fuel pressure regulator. The fuel injectors are supplied with pressurized fuel, but ex- cess fuel is diverted to the fuel tank without first passing through the fuel rail. This prevents the excess fuel from ab- sorbing heat in the engine compartment, thus lowering the temperature and amount of vaporization in the fuel tank.
160-25 Fuel Tank and Fuel pump1 The 312-way valve is also activated briefly if an engine misfire is detected. This provides full fuel flow through the fuel rail to determine if the misfire was caused by a lean fuel condition. The valve is monitored by the ECM forfaults. - Using BMW or compatible scan tool, read out fault memory. See OBD On-Board Diagnostics. - Turn off ignition. - Raise car and support safely. CA UTIOW Male sure the car is stable and well suppodedat all times. Use a professional automotive lift orjack stands designed for the purpose. A floor jack is not adequate support. - Worlting under car beneath drivers seat, remove protective panel from fuel filter and 312-way valve. - Clamp off fuel lines at 312-way valve. 4 To remove 312-way valve (V-8 model shown): Disconnect electrical harness connector (A) from valve. Remove vacuum hose (B) from fuel pressure regulator. * Remove hose clamps (arrows) and disconnect fuel lines. Remove M6 mounting nuts and lower 312-way valve. WARNING- Fuel will be spilled. Use shop rags to capture fuelas fuellines are disconnected. Do not smoke or work near heaters or oth- er fire hazards. - Installation is reverse of removal. Use new hose clamps NOTE- Install protective cover and seals correctly to keep moisture and road dirt out of underbody fuel system components. Tightening torques Hose clamps 8 - 13 mm dia. 2 Nm (18 in-lb) Hose clamps 10 - 16 mm dia. 2 Nm (18 in-lb) Hose clamps 18 mm dia. 3 Nm (27 in-lb) Hose clamps 42 - 48 mm dia. 4 Nm 136 in-ib)
176 Radiator and Cooling System General ........................... .I7 0.2 Special tools ........................ .I7 0.2 Cooling system overview (M52 TU shown. others similar) ......... .I7 0.3 Coolant pump ....................... .I7 0.3 Thermostat ......................... .I7 0.3 Mechanical thermostat (M52 engine) ..... .I7 0.4 Electrically heated thermostat .......... .I7 0.4 Radiator and expansion tank ........... .I7 0.4 Mechanical cooling fan with viscous clutch .I7 0.4 Electric (auxiliary) cooling fan ........... .I7 0.4 Transmission fluid heat exchanger ....... .I7 0.5 Warnings and cautions ................ .I7 0.7 Troubleshooting ................... .I7 0.7 Cooling system inspection ............. .I7 0.8 Cooling system pressure test ........... .I7 0.9 Combustion chamber leak test ......... .I7 0.10 Thermostat ........................ .I7 0.1 0 Cooling System Service ........... 170-10 Coolant. draining and filling (6-cylinder models) .................. 170-1 0 Coolant. draining and filling (V-8 models) . 170-12 Cooling system. bleeding ............. 170-14 Mechanical (viscous clutch) cooling fan. removing and installing ............... 170-14 Electric cooling fan. removing and installing ............... 170-15 Thermostat. removing and installing (M52engine) ....................... 170-16 Thermostat. removing and installing (M52 TU or M54 engine) .............. 170-17 Thermostat. removing and installing (V-8 models) ....................... 170-1 8 Coolant pump. replacing (6-cylinder models) .................. 170-1 9 Coolant pump. replacing (V-8 models) ... 170-20 Radiator. removing and installing ....... 170-22 Expansion tank. removing and installing . . 170-24
I Radiator and Cooling System This section covers component repair information for the en- gine cooling system. Heater core replacement is covered in 640 Heating and Air Conditioning. Special tools Special tools are necessaryfor belt-driven fan clutch removal and also for pressure testing the cooling system. 4 Cooling fan counterhold wrench (Tool No. BMW 11 5 030) 4 Cooling fan wrench (Tool No. BMW 11 5 040) < Expansion tank cap test adaptor (Tool No. BMW 17 0 007) 17 0 002 4 Cooling system pressure tester set 1 17 o 005 (Tool No. BMW 17 0 OOZi17 0 005)
- - L- - -- -. - - - Radiator and Cooling sYstelll/ -- Cooling system overview (M52 TU shown, others similar) Coolant pump A centrifugal coolant pump is mounted to the front of the en- gine. The belt-driven pump circulates coolant through the system whenever the engine is running. Thermostat Two types of thermostats are used in the cars covered by this manual. 6-cylinder models built up to 911 998 (M52 engine) use a conventional mechanical thermostat. All V-8 models and 6-cylinder models from 911998 use an electrically heated thermostat.
- I Radiator and Cooling System Mechanical thermostat (M52 engine) 4 The mechanical thermostat relies on coolant temperature to operate. While coolant is cold, it remains closed, and circu- lating coolant bypasses the radiator for rapid engine warm up. At higher coolant temperature, the thermostat progres- sively opens to allow coolant flow through the radiator, thus controlling engine temperature. Port A restricts coolant flow from radiator, and port B restricts coolant flow to radiator. Electrically heated thermostat 4 The electrically heated thermostat is DME map-controlled. The engine control module (ECM) activates the thermostat to maintain engine coolant temperature within a narrow range. In case of failure of the electronics, the mechanical function of the thermostat acts as a fail-safe. Radiator and expansion tank The radiator is a crossflow design. An expansion tank pro- vides for coolant expansion at higher temperatures and easy monitoring of the coolant level. On cars with automatic transmission, ATF is circulated through an additional heat exchanger (ATF cooler). Mechanical cooling fan with viscous clutch The mechanical cooling fan is belt-driven via a viscous fluid coupling (clutch) attached to the front of the coolant pump. The fan clutch controls the speed of the fan based on the tem- perature of the air flowing through the radiator core. Electric (auxiliary) cooling fan The electric cooling fan is mounted on the bumper side of the radiator. In models manufactured up to 911 998 (M52 or 1997 M62 en- gine), the electric cooling fan is controlled by a dual tempera- ture fan switch mounted in the side of the radiator.