Honda Bmw 5 Service Manual
Have a look at the manual Honda Bmw 5 Service Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 328 Honda manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
- 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 housing and remove cylinder. - Installation is reverse of removal, noting the following: Check for wear on slave cylinder. Any wear except on tip is caused by misalignment of clutch components. Lightly coat pushrod tip with molybdenum disulfide grease (MolyltoteIB Longterm or equivalent). . During installation be sure pushrod tip engages recess in clutch release lever. Fill fluid reservoir with clean fluid. . Bleed clutch hydraulics as described earlier. Tightening toraues - -. Clutch slave cylinder to transmission 22 Nm (16 R-lb) Fluid line to slave cylinder 17 Nm (13 ft-lb) The transmission must be removed from the engine to access the clutch mechanical components. It is recommended that the clutch disc, pressure plate and release bearing be re- placed during a clutch overhaul. Besure tocheck the bottom of the bellhousing foroil. If engine oil is found, check for a faulty rear crankshaft main oil seal. See 119 Lubrication for rear main seal replacement. Clutch variations Two versions of the clutch are used: 1997 528i (6 cylinder) uses traditional clutch components. All 540i (V-8) and 1998 and later 6 cylinder models from use a self-adjusting clutch (SAC).
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 through before starting the job. The pressure plate of the SAC uses a spring-loaded wedge rino to cornoensate for clutch disc wear. The wedge ring ad- ;u$s by means of sprng tenson, so specal toolsh~st be used to appy and relieve spring tension as the c utch pres- sure plate is installed. Self adjusting clutch (SAC) and clutch hydraulics
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 compressed air to clean components. Do not grind, heat, weld, or sand on or near anv asbestos materials. Pull release bearing off transmission input shaft. Remove clutch release lever by sliding it out of spring clip in direction of arrow. Clutch components, inspecting - Inspect clutch disc for wear, cracks, loose rivets, contamina- tion or excessive runout (warping). Replace if necessary. - Measure clutch disc lining thickness at shallowest rivet head. 7 Clutch and pressure plate wear limits Minimum clutch disc lining thickness (at rivets) 1.0 mm (0.04 in) - Maxtmum lateral runout (d~aphragm sprtngs to pressure plate) 0 6 mm (0 02 in)
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 lightly lubricate clutch disc splines and transmis- sion input shaft splines. 4 Checlc release bearing ball stud and spring retainer. Replace if damaged or worn. CAUTION-- On S6S 420G transmission, always replace release bearing ball stud and retainer spring. - Clean release bearing guide sleeve. CA U TIOG Do not grease guide sleeve. If guide sleeve is greased, release bearing may stick to it. Flywheel, removing and installing (6 cylinder engine) - lnspect flywheel for scoring, hot spots, cracks or loose or worn guide pins. Replace flywheel if any faults are found. Lock flywheel with BMW special tool 11 2 170. Remove pressure plate and clutch disc as described earlier. - Loosen and remove flywheel mounting bolts. Remove flywheel. - Clean flywheel bolt threads in crankshaft.
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 compound. 1 Flywheel, removing and installing (V-8 engine) - Inspect flywheel for scoring, hot spots, cracks or loose or worn guide pins. Replace flywheel if any faults are found. 4 Loclcflywheel with BMW special tool 11 2 070. Remove pres- sure plate and clutch disc as described earlier. - Use BMW special tool 11 4 180 (Ton. T60) to loosen and re- move flywheel mounting bolts. Remove flywheel. - Clean flywheel bolt threads in crankshaft
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 descr~bed in 230 Manual Transmis- sion. 4 If flywheel was replaced, check pulse sensor (arrow) for cor. rect installation depth. - Remove pulse sensor.
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 avail- able from BMW to adjust air gap to specification. Pulse air sensor gap End of sensor to flywheel teeth 0.55 i-0.2 rnrn (0.0217 i0.0079 in) Transmission input shaft pilot bearing, replacing - Remove clutch as described earlier. 4 Remove pilot bearing from end of crankshaft using BMW special tool 11 2 340 or equivalent puller.
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 flywheel. Install and tighten bolts hand-tight. CAUTIOG Be sure clutch disc is facing the correct way The disc should be marked kngine side or transmission side: - Tighten each clutch bolt one turn at a time until pressure plate is fully seated. Torque to specification. Tightening torques Clutch to flywheel . M8 (8.8 grade) 24 Nrn (18 ft-lb) - M8 (10.9 grade) 34 Nrn (25 ft-lb) - Remove clutch disc centering tool.
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 230 Manual Transmission . Transmission to engine MB (Torx) 22 Nm (16 fl-lb) MlO(Torx) 43 Nm (32 fl-lb) Clutch, installing (new SAC components) V-8 models and 1998 and later 6 cylinder models are equipped with the self-adjusting clutch (SAC) pressure plate. The SAC pressure plate, when new, comes from the factory with a lock plate at the center which maintains spring tension on the self-adjusting springs. This loclting ring must not be re- moved until the pressure plate is securely installed on tlie fly- wheel with the clutch disk in place. CAUTION- Avoidcontaminating clutch friction surfaces with oilorgrease. Do not touch these surfaces. < Center clutch disc on flywheel using centering tool. 5-speed transmission: Special tool 21 2 142 - 6-speed transmission: Special tool 21 2 141 G6S-3782 transmission: Special tool 21 2 201 CAUTION- Be sure clutch disc is facing the correct way The disc should be marked engine side or transmission side: The large bolt in the clutch disc centering tool is used to in- stalland remove the tool only. Once the disc is in place on the eel, remove the bolt to male room for tlie SACpressure
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 in center of pressure plate. NOTE- The spring lockplate may make snapping noises while being unscrewed. Using large bolt, pull out clutch centering tool Remove flywheel locking tool 4 Inspect and clean release bearing lever. Apply a thin coat of grease to release bearing lever lubrication points. lnstall re- lease bearing. Bearing tabs (A) align with contact points (B) on release lever. - Clean release bearing guide sleeve. CAUTIOG Do not grease guide sleeve. Ifguide sleeve is greased, re- lease bearing may stick to it. - Clean and lightly lubricate clutch disc splines and transmis- sion input shaft splines. - lnstall transmission. See 230 Manual Transmission. Tightening torques - - - Transmlsslon to engine - . MB (Torx) 22 Nm (16 it-lb) MI0 (Torx) 43 Nm (32 it-lb) * M12 (Torx) 72 Nm (53 it-lb) .-