Honda Bmw 5 Service Manual

							
Maintenance 
< Remove NC compressor belt: 
Loosen  tensioner mounting fasteners  (arrows) 
Swing tensioner down  to remove belt. 
4 To  reinstall compressor belt: 
Route  belt over pulleys. 
* Pretension belt by turning adjuster  clockwise (arrow) to 
stop. 
- Tighten tensioner mounting bolts (A). 
Tightening torques 
Fan  clutch  to coolant  pump (left- hand thread) 
with  BMW  tool 
11 5 040 
30 Nm  (22 ft-lb) 
without  BMW tool 11 5 040 
40 Nm (29 ft-lb) 
Tensioner to engine  block 
8.8 grade 
22 Nm (16 ft-lb) 
10.9 grade (Ilquid-cooled alternator) 30 Nm  (22 ft-lb) 
Idle speed 
Engine idle speed  can change due  to a number  of factors,  in- 
cluding normal  wear. The idle speed is  electronically adaptive 
and  not adjustable.  See 
130 Fuel Injection for more  informa- 
tion. 
Catalytic converter  and oxygen  sensors 
OBD II enhanced emission  standards require the  engine 
control  module (ECM) to monitor  the oxygen content  in the 
exhaust with oxygen sensors placed  before and after  the cat- 
alytic  converter. This allows  for tighter control  of tail pipe 
emissions  and also  allows  the ECM  to diagnose  converter 
problems.  If the ECM detects  that catalytic converter  or oxy- 
gen sensor efficiency  has degraded past  a certain 
prepro- 
grammed  limit, it will turn  on the  malfunction indicator  light 
(MIL),  and store a diagnostic  trouble code (DTC) in the ECM. 
See  OBD On-Board Diagnostics  for more  information on 
OBD 
ll systems. 
Replacement  of oxygen  sensors  at the  specified intervals 
he  engine  and emission control  system will   
						

							
Maintenance 
continue to operate as designed. Extending  the replacement 
interval may  void the emission control warranty  coverage. 
See 
180 Exhaust System for  information  on replacing the 
oxygen sensors. 
Tightening  torque 
Oxvoen sensor  to exhaust 
manifold 50 Nrn (37 ft-lb) 
NOTE- 
A special  soclet for replacing  the oxygen sensor  is available 
from  most  automotive  parts stores.  The  soclet has 
a groove 
cut  down  one side  to allow  the sensor  to be  installed  without 
damaging the  wire harness. 
Power  steering fluid, checking level 
The power steering system  is permanently filled  and does  not 
have a  drain. Routinely adding  ATF is not required  unless the 
system  is leaking. 
4 To  check  power steering fluid  level in fluid reservoir: 
Park  car on  level ground  with engine off. 
Level  is correct 
if it is between MlN and MAX marks  on 
dipstick. 
If  level  is below 
MlN mark,  add fluid to reservoir  to bring 
level  up. 
* Hand-tighten reservoir  cap. 
Power steering  fluid 
Dexron 
1iiO ATF  or equivalent 
Spark  plugs 
E39 models through model  year 1998  were  equipped with 
spark plugs with  two electrodes. These  are gapped to 
0.7 mm 
(0.028  in) by the manufacturer  and are not adjustable. 
Starting with 1999 models,  long life spark plugs with 
3 or four 
electrodes were  used. These can  be retroactively fitted to 
earlier 
models. The recommended  spark plug replacement 
interval 
forthese is  100,000 miles.The electrode  gap in these 
spark plugs is not  adjustable. 
Spark plug applications 
M52  Bosch FBLDCR 
M52 TU, M54 Bosch FGR7DQP or NGK BKRBEQUP 
M62 to 7/97  Bosch F7LDCR or NGK BKR6EK 
M62 from  7/97  Bosch F9LDCR 
M62 TU  Bosch FGR7DQP or NGK BKRGEQUP   
						

							
020-21 
Maintenance 
Spark plugs, replacing 
E39 engines  use a coil-over-spark  plug configuration, with 
one ignition  coil above each spark plug. Sparks  plugs should 
be removed only  after the engine has cooled. 
Remove engine 
cover(s) over ignition coils: 
Remove acoustic  cover over  fuel injectors 
I intake 
manifold. 
6-cylinder  engine:  Remove oil filler cap. 
Remove plastic  trim covers  (arrows). 
Remove cover hold-down  bolts. Remove  coil 
cover(s) 
6-cylinder  engine: Temporarily reinstall oil filler cap  to 
keep  out contaminants. 
Remove ignition  coil grounding harnesses  (arrows). 6-cylin- 
der  coils shown, 
V-8 engine is  similar. 
< Remove ignition coils: 
Pull  up on spring  clips to disconnect ignition  coil harness 
connectors. 
Remove  coil mounting  bolts. Pull coils  up and  off spark 
plugs. 
- Remove spark plugs.   
						

							
020-22 Maintenance 
1 
- Installation is reverse  of removal,  bearing in mind  the 
following: 
Lightly lubricate  new 
spark plug  threads  with 
copper-based  anti-seize compound. 
Thread plugs into  cylinder head by hand  to prevent 
cross-threading. 
. Be  sure  to reinstall and tighten  coil grounds. 
Tightening torque  Spark  plug 
to cylinder head 25 Nm (18 It-lb) 
Interior ventilation microfilter, replacing 
Two interior  ventilation microfilters  are used,  one on each 
side  of the engine  compartment  at the  fire wall. 
< To replace  the microfilter, unclip  the wire fastener  and 
remove  the cover. 
Lift out  the filter,  and replace. Left  side shown;  right is 
similar. 
Replace  cover and clip wire fastener  to retain  cover. 
Battery, checking, cleaning, and replacing 
The battery Is located  in the  right side  of the  luggage compart- 
ment. Simple  maintenance of the  battery  and its terminal 
connections  will ensure maximum starting  periormance, 
especially  in winter when colder temperatures reduce battery 
power. 
Battery  cables should be  tight. The terminals,  cable clamps 
and  battery case  should be free of  the white  deposits that 
indicate corrosion  and acid salts. Even a  thin layer  of dust 
containing  conductive  acid salts can cause  battery discharge.   
						

							
Maintenance 
- To remove battery corrosion: 
Disconnect battery  cables. Disconnect negative  (-)cable 
first. 
* Remove  battery from trunk 
Clean terminal posts and  cable clamps with a  wire brush. 
Clean main chassis ground terminal  next to battery. 
Corrosion can be washed  away with a 
baking soda and 
water  solution  that will neutralize  acid. 
Reinstall battery and  reconnect cable clamps, positive 
(+) 
cable first. 
Lightly coat outside  of terminals,  hold down screws,  and 
clamps with petroleum  jelly, grease, or  a commercial 
battery terminal corrosion  inhibitor. 
WARNING 
- 
Battery  acid is extremely  dangerous.  Take care to keep it 
from  contacting  eyes, skin, or clothing.  Wear eye  protection. 
Extinguish  all 
smolihg materials and do not  work  near any 
oaen flames. 
CAUTION- 
Prior  to disconnecting  the batteg read the battery  discon- 
nection  cautions  given in 
001 General  Cautions  and 
Warnings. 
NOTE- 
The  original equipment battery  in E39 models is mainte- 
nance  free. The original  electrolyte will normally  last the 
entire service  life of the  battery under moderate climate  con- 
ditions. 
Battery  electrolyte should be maintained at the correct level 
just above the battery plates  and theirseparators. The  correct 
level is approximately 
5 mm (14 in.)  above the  top of battery 
plates  or to the  top of the indicator 
marks (if applicable). The 
battery plates and the indicator  marks can be  seen once  the 
fillercaps  are removed. 
if theelectrolyte level  is low, replenish 
it  by  adding distilled water only. 
4 The original equipment  BMW battery is equipped  with a 
built-in hydrometer magic  eye 
(arrow). Battery condition is 
determined  by the color  of the  eye: 
Green:  Adequate charge 
* Black: Inadequate charge, recharge 
Yellow:  Defective  battery,  replace 
Batteries are rated  by ampere hours (Ah),  the number of 
hours a  specific  current drain can  be sustained before  com- 
plete  discharge, or by  cold cranking amps (CCA), the number 
of  amps  available  to crank the  engine in cold weather 
condi-   
						

							
020-24 
Maintenance 
tions. In general, replacement batteries should always  be 
rated equal  or higher  than the original  battery. 
The battery  is held  in place  by a single hand screw  and plate. 
A secure battery hold-down  is important  in order to prevent 
vibrations and road shoclt  from damaging the battery. 
CAUTION- 
Prior  to disconnecting  the baitem read the battery  discon- 
nection cautions  given in 
001 General  Cautions  and 
Warnings. 
NOTE- 
Always disconnect  the negative (-) cable  first, and connect 
it  last.  While  changing the battery, clean  away any corro- 
sion  in or  around  the battery tray 
More battery  and charging system information  is in 121 
Battery,  Alternator,  Starter. 
Brake fluid,  replacing 
Brake fluid absorbs moisture  easily, and moisture  in the  fluid 
affects bralte performance  and reliability. This is  why 
BMW 
strictly recommends replacing the bralte fluid every  two 
years.  When replacing  or adding bralte fluid, use  only new 
fluid from previously unopened containers.  Do not use brake 
fluid  that has  been bled from the system, even 
if it is  brand 
new.  Use only DOT 
4 brake  fluid. 
NOTE- 
See 340 Brakes for brake fluid flushing procedures. 
Brake  pad 1 rotor wear,  checking 
Disc brakes are fitted at all  four wheels.  Although the brakes 
are equipped with a brake pad warning system,  the system 
only monitors  one wheel  per axle.  Pad thickness  should be 
checked whenever wheels  are off or brake 
worlt is being 
done. 
4 Disc  brake  pad wear  can be checked through opening  in 
caliper: 
Measure distance 
(A) of  brake  pad eai to bralte  rotor. 
See 
340 Brakes.  Compare to specification  below.   
						

							
7 Maintenance 
< Unbolt caliper from steering arm  to properly  inspect: 
Brake  pad thickness 
(A) 
Brake rotor 
Condition  of caliper seal 
(B) 
Condition of caliper slider bolts (C) 
NOTE- 
Brake caliper  removal and installation procedures are given 
in 
340 Brakes. 
Brake pad lining  minimum  thickness 
Dimension 
A 3.0 mm (0.12 in) 
Brake system, inspecting 
Routine maintenance  of the brake system includes  maintain- 
ing  the  brake fluid in  the reservoir, 
checking bralte  pads for 
wear, checking parking brake  function, and inspecting the 
system for fluid lealts  or other damage: 
- Check that bralte hoses are correctly routed to  avoid chafing 
or 
Itinking. 
- lnspect unions and brake  calipers for signs of fluid  leaks. 
- lnspect rigid lines  for corrosion,  dents, or other damage. 
- Inspect flexible hoses  for cracking 
- Replace faulty hoses  or lines  as described  in 340 Brakes. 
WARNING- 
Incorrect installation  or overtightening  hoses,  lines, and 
unions  may cause  chafing 
orlealage. This can lead  to partial 
Parking brake, checking 
The parking brake system  is independent  of the main braking 
system and  may require periodic  adjustment depending on 
use.  Adjust  the parking brake  if the brake  lever can be pulled 
up more  than 
8 clicks. Check  that the cable moves freely.  A 
description  of the parking brake  and 
parlting bralte adjust- 
ment can  be found in 
340 Brakes.   
						

							
020-26 
Maintenance 
NOTE- 
The parking  brake may  lose some  of its  effectiveness  if it is 
not  used  frequently  This is due to corrosion build-up  on the 
parking  brake drum.  To remove  corrosion,  apply the parking 
brake  just until  it begins  to grip, then pull the lever  up one 
more stop  (click). Drive the car approximately  400 meters 
(1,300 
ft.) and  release  the brake. To recheck  the adjustment 
of  the  parking  brake see 
340 Brakes. 
Clutch fluid, checking 
In cars equipped with  manual transmission  and clutch, the hy- 
draulic clutch  and the brake  system share  the same reservoir 
and  the same  bralte fluid. Clutch  fluid level and  brake fluid lev- 
el  are  checked  at the same  time. 
NOTE- 
* See 340 Brakes for more  information. 
See 
210 Clutch for  information  on the  clutch  and the 
hydraulic clutch operating  system. 
Differential oil level, checking 
The E39  differential  is filled  with lifetime oil that  ordinarily 
does  not need to  be changed. 
BMW recommends  using only 
a  specially formulated  synthetic gear oil 
(SAF-XO) that is 
available through  an authorized 
BM\N dealer  parts depart- 
ment.  For additional information  on this lubricant and  any 
other lubricants that  may be compatible, contact an 
authorized 
BMW dealer service department. 
< Check rear  differential oil  level at filler plug (arrow). 
- Check  lubricant  level with car on a level surface: 
Level  is correct  when fluid just reaches  edge of filler  hole. 
If necessary,  top up fluid. 
Replace filler plug  sealing ring. 
Install and tighten oil  filler plug  when  oil level is  correct. 
NOTE- 
Use either  a 14  mm  or 17 mm Allen  socket  to remove  the 
drain plug. 
If  the  car is raised  in the  air, it should  be level  when 
checking  or filling final  drive fluid level. 
Tightening torque 
Filler plug to final drive housing 70 Nrn (52 it-lb)   
						

							
.-. - 
Maintenance 
Drive axle joint 
(CV joint)  boots, inspecting 
CVjoint protective  boots must be closely inspected  forcracks 
and any other damage  that will allow contaminants to  get into 
the  joint. 
If the  rubber boots  fail, the water and dirt that  enter 
the  joint will quickly damage it. 
NOTE- 
Replacement  of the CVjoint boots  and inspection  of the 
joints  are described 
in 331 Final Drive. 
Exhaust system, inspecting 
Exhaust system  life varies widely according  to driving habits 
and  environmental conditions.  If short-distance driving  pre- 
dominates, the  moisture and condensation  in the system will 
not fully dry  out. This will  lead to early corrosion damage and 
more frequent  replacement. 
Scheduled  maintenance  of the exhaust system  is limited to 
inspection: 
* Check  to see that all the  hangers (arrow) are in place and 
properly supporting the  system and that the system does 
not strike  the body. 
Check  for restrictions due to dents or 
kinlts, 
Check for weakness  or perforation due to  rust. 
NOTE- 
Alignment of the system  and the location  of the hangers  are 
described  in 
180 Exhaust System. 
Fuel filter, replacing 
The fuel  filter is located beneath the center  of the  car,  approx- 
imately under  the drivers  seat. 
A protective cover must  be 
removed  to access  the filter. 
4 Fuel  filter for M62 engine  (arrow) 
- Disconnect  battery negative (-) cable 
CAUTIOI\C 
Disconnecting the battery  cables may erase  fault codes 
stored 
in engine control module  memory. 
WARNING - 
Fuel will be expelled  forcibly when  the  filter is removed.  Do 
notsmoke or work  near heaters orother fire hazards. Keep a 
fire extinguisher  handy   
						

							
020-28 
1 Maintenance 
- When replacing fuel filter: 
Use appropriate hose  clamping device to clamp  off filter 
inlet and  outlet hoses  to lessen  fuel spillage. 
Loosen center clamping  bracket and hose  clamps on 
either end  of filter. 
Note  arrow or  markings indicating  direction of flow  on 
new  filter. 
Install  new filter using  new hose clamps 
- Drain  fuel filter  from inlet  side into a  container  and inspect 
drained  fuel. 
Checlc for rust,  moisture and  contamination. 
I - I < If fuel  filter  is equipped with  fuel pressure regulator: 
I 2 / Remove vacuum hose (1) 
Pull out locking clip (2). 
- Remove fuel  pressure regulator (3). 
Install pressure  regulator in new  filter. 
Clean thoroughly  around the filler  connections before 
removing  them. 
After  assembly,  check filter connections carefully  for 
I 
I lealcs before installing cover. 
NOTE- ~- 
Additional informarion about  the fuel filler  assembly  is in 160 
Fuel Tank and Fuel  Pump. 
Fuel tank and fuel lines,  inspecting 
lnspectthe fuel tank, fuel lines, and fuel  system fordamage  or 
lealts. Checlc for fuel lealts in the engine compartment  or fuel 
odors  in the passenger compartment. Check for  any evapora- 
tive  emissions hoses  that may  have become disconnected, 
checking carefully  at charcoal canister  and evaporative emis- 
sions purge  system. See 
130 Fuel Injection  and 160 Fuel 
Tankand Fuel Pump  for component locations  and additional 
information. 
WARNING- 
When checlcing  for fuel leal(s, the engine  must be cold.  A hot 
exhaust  manifold  or exhaust  system could cause  the fuel to 
ignite  or explode  causing serious personal injury  Ventilate 
the  work  area and clean  up spilled  fuel immediately.