Honda Bmw 5 Service Manual
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Two common causes of driveability problems are incorrect system voltage and bad grounds. System voltage Digital motor electronics (DME) requires that the system (bat- tery) voltage be maintained within a narrow range of DC volt- age. DC voltage levels beyond or below the operating range, or any AIC voltage in the electrical system can cause havoc. When troubleshooting an illuminated MIL, make sure the bat- tery is fully charged and capable of delivering all its power to the electrical system. An undercharged battery can amplify AIC alternator output ripple. To make a quick check of the battery charge, measure the voltage across the battery terminals with all cables attached and the ignition off. Afully charged battery will measure 12.6 volts or slightly more, compared to 12.1 5 volts for a battery with a 25% charge. The DME system operates at low voltage and current levels, making it sensitive to small increases in resistance. The elec- trical system is routinely subjected to corrosion, vibration and wear, so faults or corrosion in the wiring harness and connec- tors are not uncommon. Check the battery terminals forcorro- sion or loose cable connections. See 121 Battery, Starter, Alternator for additional information. If a battery cable connection has no v~sible faults but is still suspect, measure the voltage drop across the connection. A large drop indicates excessive resistance, meaning that the connection is corroded, dirty, or damaged. Clean or repairthe connection and retest. NOTE- For instructions on conducting a voltage drop test and other general electrical troubleshooting information, see 600 Elec- trical System-General. Visually inspect all wiring, connectors, switches and fuses in the system. Loose or damaged connectors can cause inter- mittent problems, especially the small terminals in the ECM connectors. Disconnect the wiring harness connectors to check for corrosion, and use electrical cleaning spray to re- move contaminants. Main grounds Good grounds are critical to proper DME operation. If a ground connection has no visible faults but is still suspect. measure the voltage drop across the connection. A large volt- age drop means high resistance. Clean or repair the connec- tion and retest. LBuntr.yP~sbhnllcn.can#-AII A,~iltl Rcsrwsd
100-6 ( Engine-General The main grounds for the fuel and ignition circuits of the DME system are illustrated below; see 610 Electrical Component Locations for additional ground and component locations. 4 Ground for engine management system in right rear of en- gine compartment on E-box bulkhead (arrow). 6-cylinder models: Grounds for ignition coils (arrows) 4 V-8 models: Grounds for ignition coils, at cylinders 3 (arrow) and 7. 4 Fuel pump ground (arrow) below right tail light in luggage compartment. NOTE- Ground location for sedan shown, wagon models may differ.
11 0 Engine Removal and installation General ........................... .I1 0-2 Engine, Removal and Installation ........................ Special tools .I 10-2 (V-8 models). ..................... 11 0-1 6 Engine, Removal and Installation ....................... (6-cylinder) .I1 0-3
I Engine Removal and Installation Engine removal and installation are covered in this repail group. See 100 Engine-General for engine identification details and engine codes. Transmission removal is required for all models before the engine can be removed. This is best accomplished with the car raised on an automotive lift. For additional procedures re- quired during engine removal, refer to the following repair groups: 020 Maintenance 0 121 Battery, Alternator, Starter 170 Radiator and Cooling System 180 Exhaust System 4 230 Manual Transmission 0 240 Automatic Transmission 410 Fenders, Engine Hood Special tools Some special tools are required for engine removal and in- stallation. Be sure to have the necessary equipment on hand before starting the job. Engine lifting tool (Tool No. BMW 11 0 000) 4 Cooling fan counterhold tool (Tool No. BMW 11 5 030) < Cool~ng fan wrench (Tool No. BMW 11 5 040)
110-3 Engine Removal and lnstallationl Q Fuel line plugs (Tool No. BMW 13 5 281 / 13 5 282) 4 Fuel line removal tool (Tool No. BMW 16 1 050) CAUTION- Disconnecting the battery may erase fault code@) storedin memoiy Check for fault codes prior to disconnecting the battery cables. If the MIL (Malfunction Indicator Light, also may be called Check Engine or Service Engine Soon light) is illuminated, see OBD On-Board Diagnostics for DME fault code information. It orhersysrem faults have been detected, as indicated I by an ~llum~nated ABS, SRS orASC/DSC ~arning light, see the appropriate repair group in this manual or an authorized BMW dealer for more information on fault codes. NOTE- Engine removal procedures are similar for all 6-cylinder models. When differences exist, they are noted at the be- ginning of each step. Engine are referred to by engine code. See 100 Engine-General for engine code and appli- cation information. @ Be sure to cover all painted surfaces before beginning the removal procedure. As an aid to installation, label all com- ponents, wires and hoses before removing them. Do not reuse gaskets, O-rings or seals during reassembly. The intake manifold must be removed on &cylinder mod- els before the engine can be removed. WARNING- Due to risk of personal injury, be sure the engine is cold be- fore beginning the removal procedure.
11 0-4 /Engine Removal and Installation - Disconnect negative (-) cable from battery. CAUTION- Prior to disconnecting the batteg read the battery discon- nection cautions in 001 General Cautions and Warnings. - Remove engine hood, or place in service position. See 410 Fenders, Engine Hood. 4 Remove left and right interior ventilation ducts (lefl side shown): Release ventilation filter cover latch (A) and remove cover. Release plastic loclting tab (6) or release locking tabs on top of duct (later models). Rotate duct counterclocltwise to unloclt from bulkhead and remove (arrow). Disconnect electrical harness from hood switch (C). Release spring loclt (D). Slide filter housing away from inner fender to remove. Removal of right side ventilation duct is similar. Remove rear bulkhead panel: Remove rubber sealing gasket (arrow). - Remove 3 mounting clips (A). Remove 4 retaining screws (6). Lift off panel. Remove complete air filter housing: Loosen intalte duct hose clamp (A) at throttle assembly. Loosen clamp and remove idle control line from intalte duct (6) and (where applicable) disconnect idle speed control valve electrical harness connector. Disconnect harness connector (C) from mass air flow sen- sor. 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.
Engine Removal and lnstallationl < Remove positive battery cable and intake manifold cover: Remove protective cover from positive (+)jump start post (4. Loosen and remove battery lead mounting nut. Remove lead and push down through intake manifold Remove trim covers (arrows) from fuel injector cover. Remove cover hold down bolts and lift off cover. Working above engine, disconnect the following: Vent line from cylinder head cover (A). M52 engine: Oxygen sensor connectors (8). Electrical harness connector from intalte camshaft VANOS solenoid valve (C). M52 engine: Disconnect electrical harness connectors at throttle valve position switch (D), ASC valve position switch (E), fuel injector harness (F) and vent valve (G). CAUTION- Be sure to mark oxygen sensor harness connectors so that they can be reassembled correctly Do not interchange con- nectors. 4 M52 TU, M54 engine: Disconnect fuel injector electrical con- nectors from injectors. Use small screwdriverto pry one corner of wire lock clip on fuel injector 1 connector. Repeat for all injectors. Lifl off connector loom and lay aside.
. .- - I Engine Removal and Installation I 4 Where applicable, remove schraedervalve cap (arrow) from air connection on fuel rail. Using a tire chuck, blow fuel back through feed line using a brief burst of compressed air (rnax- imum of 3 bar or 43.5 psi). WARNING - Fuel in fuel line is under pressure (approx. 3 - 5 bar or 45 - 75psi) andmay be expelled underpressure. Do not smoke or work near heaters or other fire hazards. Keep a fire ex- tinguisher handy Before disconnecting fuel hoses, wrap a cloth around fuel hoses to absorb any leaking fuel. Catch and dispose of escaped fuel. Plug all open fuel lines. Alwavs unscrew the Fuel tank cao to release oressure I in the tank before working on the tank or lines. I - Raise car and support in a safe manner. WARNING- Male sure the car is stable and we/ supported at all times. Use a professional automotive lift orjackstands designed for the purpose. A floor jack is not adequate support - Working underneath car, remove protective engine splash guard. 4 Disconnect fuel lines by sliding locking collar in (arrows) and pulling line apart.
Engine Removal and lnstallationl NOTE- BMW uses three styles of fuel line connections; a one-time single use clamp, a locking fitting that uses special tool 16 1 050 to release, and a quick release sleeve (arrow) that dis- connects the line when depressed. WARNING- Fuel may be expelled under pressure. Do not smoke or work near heaters or other fire hazards. Keep a fire extinguisher handy Before disconnecting fuel hoses, wrap a cloth around fuel hoses to absorb any leaking fuel. Plug all oDen fuel lines. < M52 engine: Remove throttle valve and ASC throttle assemblies. Disconnect ASC throttle cable (A). Remove ASC throttle housing mounting fasteners (El). Clamp off, disconnect, and plug coolant hoses (C). Disconnect throttle and cruise control cables (D). Remove throttle housing mounting hardware and throttle valve. NOTE- M52 TU, M54 engine: Throttle body is removed with intake manifold. < M52 TU engine: Pull throttle cable out of rubber retainer (A) and unloclc ball end of cable (6) from throttle actuator.
110-8 1 Engine Removal and Installation 4 M52 TU, M54 engine: Remove fasteners (arrows) retaining wiring harness conduit to throttle body. 4 M52 TU, M54 engine: Working at throttle housing, rotate har- ness plug (arrow) counterclockwise and remove. 4 M52 TU, M54 engine: Disconnect electrical harness connec- tor at idle speed control valve (arrow), directly above throttle valve.