Removal and Replacement

ENGINE REMOVAL

NOTE: If jobs have to be performed on a removed engine, which make it necessary to unscrew the central vibration damper mounting bolt, it must be loosened prior to removal of the engine. This bolt is torqued with about 800 Nm (578 ft.lbs.) and therefore too difficult to loosen on a removed engine. Tighten the central bolt after installation of the engine (loosening is in reverse order). Procedures

CAUTION: Disconnecting the battery will cancel (clear) the memory of control units which have diagnostic trouble code capabilities. Be sure to interrogate all control units for possible diagnostic trouble codes prior to disconnecting the battery.

BMW anti-theft radios can be rendered useless by disconnecting the battery. Make sure you know the correct code before disconnecting the battery. See your owner's manual for more information.

- Disconnect battery ground lead.
- Remove Transmission

NOTE: Always use Special Tool 23 1 330 for removal of the transmission.

- Remove engine hood.

NOTE: Supply lines of windshield spray jets do not have connection points, so that the windshield washing hose and wire harness for spray jet heating have to be removed prior to removal of the engine hood.

- Remove radiator with engine oil cooler and fan cowl.

- Drain remaining coolant on engine block.

Remove Fan:
- Counterhold on pulley with Special Tool 11 5 030 and unscrew coupling nut (1).

CAUTION: Left-hand threads; turn clockwise to unscrew.

Installation Note: Tighten fan with Special Tool 11 5 040 to 40 Nm (29 ft.lbs.) Tightening torque is equal to 30 Nm (22 ft.lbs.) setting on a torque wrench.

Remove Air Guide for Alternator:
- Unscrew air guide.
- Loosen hose clamps.
- Take off air guide together with connectors.

Remove Power Steering Pump:
- Loosen bolts (1) and nut (2).
- Turn tensioning pinion and take off drive belt.
- Unscrew bolts and take off power steering pump.
- Hoses remain connected.

Installation Note:
- Tighten drive belt.
- Tighten toothed element with torque of 8 to 8.5 Nm (5.8 to 6.1 ft.lbs.) and lock.
- Check drive belt tightness with special tool 11 5 020, correcting if necessary.
- Hook (4) bears on tip of a tooth.

CAUTION: Remove the tester to tighten the belt and apply it again only after tightening has been completed.

Remove A/C Compressor:
- Loosen air pump bolts.
- Turn tensioning pinion and take off drive belt.

- Unscrew compressor.
- Refrigerant hoses remain connected.

- Unscrewing engine mounts
- Unscrew ground strap on engine carrier.

Remove Air Cleaner and Air Flow Sensor:
- Take off cover for headlights.
- Pull off plugs.
- Loosen nuts.
- Loosen hose clamps.
- Lift out air cleaner with air flow sensor.

- Pull off intake air temperature sensor plug.

Disconnecting Throttle Cable and Cruise Control Cable.
- Unscrew holder.
- Unclip cables on throttle valve lever.

Disconnecting Coolant Hoses
- Disconnect hoses and plug on expansion tank.
- Remove expansion tank.

- Disconnect coolant hoses on heater and heater valve.

Note: Tilt engine forward as far as possible by inserting a wooden wedge in addition to Special Tool 23 1 330.

Disconnecting Vacuum Hose for Brake Booster
- Pull connector out of the brake booster.

- Loosen hose clamps.
- Disconnect Air Pump supply hose on air cleaner.

- Disconnect Fuel Pipes and Hoses; 1 = Feed; 2 = Return

NOTE: Arrangement of Fuel Pipes on Tank; Pipes: 1 = Feed; 2 = Return

- Disconnect tank venting hose on valve.

- disconnect engine wire harness in car.
- Lift out covers.
- Unscrew starter lead on connection point.

- Lift out cover.

- Remove covers.

- Unscrew cover on electronic box.

- Pull off ignition leads on ignition coil.
- Lift off cap.

- Unscrew leads (1 and 15) on ignition coil.
- Unscrew electric lead on ground connection point.

- Unscrew holder.
- Remove all electric lead straps.

- Pull off plug on control unit.
- Disconnect plugs (1 and 2).

- Unscrew electric lead on positive (+) connection point.
- Lift out relays (1...3) with sockets.
- Disconnect plugs (4 and 5).
- Pull off plug on temperature sensor (6).

- Unscrew relay holder.

- Lift out control unit located underneath.
- Pull off plug.

- Unscrew holder for rubber grommets.

Installation Note::
- Insert retaining pin in provided bore.

- Pull out wire harness with rubber grommet.

NOTE:
- Suspend the wire harness remaining in the car on the engine compartment wall with a piece of wire.

- Unscrew diagnosis socket.
- Disconnect engine wire harness plug (bayonet connection).

- Unscrew holder.

- Loosen electric lead straps.
- Pull out wire harness.

- Attach Special Tool 11 0 020 on engine.
- Lift out engine.

CAUTION: Guide the rear chain between the intake neck and check valve.

Installation Note: Check power steering and air conditioner hose routing.

- Reinstall components in reverse order of disassembly, paying close attention to installation notes and torque specs.