Honda Bmw 5 Service Manual
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![Page 521
170-25
Radiator and Cooling system]
< Disconnect expansion tank:
Remove expansion tank bleed screw and support clip
(A)
Loosen hose clamp (6) and disconnect coolant hose from
expansion tank.
Disconnect harness connector from coolant level sensor
(C).
Push top of expansion tank toward engine and disconnect
bleed hose.
Lift expansion
tank to free it from lower mounts, then lift
straight up to remove.
- Installation is reverse of removal, noting the following:
Fill radiator...](http://img.usermanuals.tech/thumb/34/100712/w64_bmw-5-service-manual-1509562501_d-520.png "Page 521
170-25
Radiator and Cooling system]
< Disconnect expansion tank:
Remove expansion tank bleed screw and support clip
(A)
Loosen hose clamp (6) and disconnect coolant hose from
expansion tank.
Disconnect harness connector from coolant level sensor
(C).
Push top of expansion tank toward engine and disconnect
bleed hose.
Lift expansion
tank to free it from lower mounts, then lift
straight up to remove.
- Installation is reverse of removal, noting the following:
Fill radiator...")
170-25 Radiator and Cooling system] < Disconnect expansion tank: Remove expansion tank bleed screw and support clip (A) Loosen hose clamp (6) and disconnect coolant hose from expansion tank. Disconnect harness connector from coolant level sensor (C). Push top of expansion tank toward engine and disconnect bleed hose. Lift expansion tank to free it from lower mounts, then lift straight up to remove. - Installation is reverse of removal, noting the following: Fill radiator and cooling system as described earlier. See Coolant, draining and filling (6-cylinder models) or Coolant, draining and filling (V-8 models).
180 Exhaust System General Exhaust System . . . . . . . . . . . . . . . . . Exhaust system, removing and installing Muffler, replacing.. . . . . . . . . . . . . . . . . . Exhaust Manifolds . . . . . . . . . . . . . . . Exhaust manifolds, removing and installing (M52 engine) . . . . . . . . . . Exhaust manifolds, removing and installing (M52 TU and M54 engines) . . . Exhaust manifolds, removing and installing (M62 engine) . . . . . . . . . . Oxygen Sensors. . . . . . . . . . . . . . . . . . . . 180-9 Oxygen sensors (precatalyst), replacing (M52 TU and M54) . . . . . . . . . . . . 180-9 Oxygen sensors (post-catalyst), replacing (M52 TU and M54) . . . . . . . . . . . . 180-9 Oxygen sensor, replacing (M52 and M62 engine) . . . . . . . . . . . . . . . 180-10 Exhaust System Diagrams . . . . . . . . . 180-1 1 M52 engine (528i 1997-1 998) . . . . . . . . . . 180-1 1 M52 TU and M54 engines (528i 1999-2000 and 5251 2001-2003) . . . 180-1 2 M54 engine (530i 2001-2003) . . . . . . . . . . 180-1 3 M62 engine (540i 1997-1 998) . . . . . . . . . . 180-1 4 M62 TU engine (540i 1999-2003 . . . . . . . 180-1 5
180-2 Exhaust System The exhaust system is designed to be maintenance free, al- though regular inspection is warranted due to the harsh oper- ating conditions. Under normal conditions, the catalytic converter does not require replacement unless it is damaged. New fasteners, clamps, rubber mounts and gaskets should be used when replacing exhaust components. A liberal appli- cation of penetrating oil to the exhaust system nuts and bolts in advance may make removal easier. WARNING - The exhaust system and catalytic converter operate at very high temperatures. Allow components to cool before servicing. Wear protective clothing to prevent burns. Do not use flammable chemicals near a hot cataiyiic converter. Corroded exhaust system components crumble easily and often have exposed sharp edges. To avoid injury, wear eye protection and heavy gloves when working Exhaust system, removing and installing The removal and installation procedures given here are gen- eral procedures for all models. The removal of the exhaust system as a complete unit is recommended. Once the com- plete system is removed from the car, individual pipes and mufflers can be more easily replaced. WARNING- Exhaust gases are colorless, odorless, and very toxic. Run the engine only in a well-ventilated area. Immediately repair any leaks in the exhaust system or structural damage to the car body that might allow exhaust gases to enter the passen- ger compartment. CAUTION- Use care not to drag or bang oxygen sensors. Oxygen sen- sors can be easily ruined.
... . Exhaust System - With exhaust system fully cold, raise and support car for ac- cess to exhaust system. WARNING - Do not worlc under a lifted car unless it is solidly supported on jack stands designed for that purpose. Never work under a car that is supported solely by a jack. - Disconnect oxygen sensor connector(s). 4 Loosen and remove bolts holding front exhaust pipes to ex- haust manifolds (arrows). Right side of V8 model shown. - Support exhaust system - Where applicable, disconnect exhaust support bracket as- sembly from transmission. < Remove hangers by prying off bracket (arrows). - Lower exhaust system as a single unit to ground. NOTE- If the catalytic converterlfront exhaust pipe assembly is to be replaced, transfer the oxygen sensors to the new pipe(s). Tightening torque Oxygen sensor 55 Nm (41 ft-lb) - installation is reverse of removal. * Make sure there is at least 20 mm (314 in.) clearance be- tween exhaust system and car body at every point. Loosely install ail exhaust system mounting hardware and hangers before tightening fasteners to their final torque. Coat manifold studs with copper paste before installing nuts. NOTE- Where applicable, tighten front pipe with semi-flexible com- pensator last when installing front pipe to manifolds. Tightening torques Exhaust manifolds to cylinder head 22 Nm (1 7 It-lb) Front exhaust pipe to manifolds 30 Nm (22 ft-lb) To prevent exhaust system rattles and vibration, the system should be slightly preloaded by pushing the rear clamping brackets forward about 7 mm (114 in).
/Exhaust System Muffler, replacing BMW offers individual mufflers as replacement parts for the original one-piece assembly. Replacement of a rear muffler may be possible with the system installed on the car. Re- placement of the front or middle muffler should only be done with the exhaust removed from the car. < Mark length of new muffler pipe(s) on old system. - Use exhaust pipe cutter to cut pipe(s). Deburr cut pipe end@). 4 Use clamping sleeves to join new pipe(s) to old. Make sure pipe ends are centered inside sleeve. Point clamping sleeve bolt threads (arrows) down. - Reinstall exhaust system.
Exhaust system1 Exhaust manifold removal procedures are organized accord- ing to engine code. If necessary, see 100 Engine-General for engine code and application information. Exhaust manifolds, removing and installing (M52 engine) 4 Exhaust manifolds for the M52 engine. Always use new retaining nuts and gaskets when removing and installing the exhaust manifolds. - With exhaust system cold, raise and support car for access to exhaust system. WARNING - Do not work under a lined car unless it is solidly supported on jack stands designed for that purpose. Never work under a car that is supported solely by a jack. - Disconnect secondary air check valve and pipe from exhaust manifold. - Unbolt front exhaust pipe@) from exhaust rnanifold(s) - Remove exhaust support bracket from transmission. - Loosen and remove nuts from exhaust manifolds and remove manifolds. Discard nuts and gaskets. NOTE- On cars with oxygen sensors mounted in the exhaust mani- folds, use care when removing manifolds. To be safe, remove the sensors from the manifolds before removing manifolds. - Installation is reverse of removal Coat exhaust manifold mounting studs with copper paste before installing new nuts. Install manifold gaskets with arched side facing manifolds. Tightening torque Exhaust manifolds to cylinder head 20 Nm (15 ft-lb)
180-6 Exhaust System Exhaust manifolds, removing and installing (M52 TU and M54 engines) I Exhaust manifolds with converters I 4 The exhaust manifolds incorporate the catalytic converters. Two precatalyst and two post-catalyst oxygen sensors are mounted in the exhaust manifold assembly. Under normal conditions, the catalytic converters do not re- quire replacement unless damaged. Always use new retain- ing nuts and gaskets when removing and installing the exhaust manifolds. I\ 1 4 Using engine support equipment (BMW special tools 00 0 200. 00 0 201. 00 0 202.00 0 204.00 0 208 or equivalent). connect to lifting eye on front of engine. Rhise engine approx. /I 1 5 mm (IH in). With exhaust system cold, raise and support car for access to exhaust system. WARNING- Do not worlc undera liftedcar unless it is solidly supported on jack stands designed for that purpose. Never worlc under a car that is supported solely by a jaclc. in order to avoid damaging oxygen sensors: - Detach oxygen sensor harness connectors, Remove oxygen sensors from exhaust manifolds as de- scribed later in this group. Unbolt and remove secondary air checkvalve and pipe from right front of cylinder headlexhaust manifold. Working underneath car, unbolt front exhaust pipes from ex. haust manifolds. With engine supported from above, remove right engine mount bracket and right engine mount (arrow). Loosen and remove nuts from exhaust manifolds and remove manifolds. Discard nuts and gaskets. CA UTIOG Take care tliat the front and rear oxygen sensor connectors are not mixed up. -
1 Exhaust ~vsteml NOTE- The front exhaust manifold must be removed before the rear manifold. - Installation is reverse of removal. Coat exhaust mounting studs with CRC or equivalent cop- per paste. Use new gasltets and self-locking nuts. Tightening torques Exhaust manifold to cylinder head 20 Nm (15 ft-lb) Front exhaust pipe to manifold 30 Nm (22 ft-lb) Oxygen sensor to manifold 50 Nrn (37 ft-lb) Exhaust manifolds, removing and installing (M62 engine) Always use new retaining nuts and gasltets when removing and installing the exhaust manifolds. NOTE- Access to manifolds is extremely limited. If removing exhaust manifolds as part of additional engine worlc (such as cylinder head removal), it may be easier to first remove engine. - With exhaust system cold, raise and support car for access to exhaust system. WARNING - Do not work undera lifted car unless it is solidly supported on jaclt stands designed for the purpose. Never worlc undera car that is supportedsolely by a jack. - Remove exhaust system. See Exhaust system, removing and installing. - Removing right side exhaust manifolds (cylinder bank 1-4): Remove heat baffle plate. Disconnect plug connection to oxygen sensor. securing exhaust manifolds to head. Remove manifolds towards bottom. - Installation is the reverse of removal. Coat exhaust mounting studs with CRC or equivalent copper paste. Use new gasltets and self-loclting nuts.
- Removing left side exhaust manifolds (cylinder bank 5-8): - Remove heat baffle plate on left side. Remove oxygen sensor using BMW special tool 11 7 030 or similar oxygen sensor socket. Install BMW special tools 00 0 200,OO 0 201,OO 0 202,OO 0 204, and 00 0 208 or other suitable engine lifting support above engine and attach to lifting eye on left head. NOTE- The supports on special tool 00 0 208 must rest on the screws on the fenders. - Remove nut at top of engine support on left side - Raise engine at front suspension lug a maximum of 25 mm (I .O in). Release clamping bolt and nut (arrow) and slide universal joint off steering gear. 4 Remove nuts securing left exhaust manifold to head, Raise front of manifold as high as possible past end posi- tion of steering gear and feed out towards bottom. - Installation is reverse of removal. Coat exhaust mounting studs with CRC or equivalent copper paste. Use new exhaust gaskets and self-locking nuts. Install new self-locking nuts on engine mount and steering shaft bolt.