Engine Removal and Installation
REMOVING AND INSTALLING ENGINECAUTION: 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 negative battery lead.
- Disconnect positive battery lead.
- Remove battery.
- Remove battery tray.
- Lift engine hood into assembly position and remove firewall (air manifold).
- If applicable, unscrew and remove splash guard.
- Remove transmission.
- Unfasten drain plug for coolant in engine block. Drain off coolant and dispose of correctly.
Installation Note: Replace seal. Torque drain plug to 40 ± 5 Nm (30 ± 3 ft lbs).
- Remove covers.
- Remove intake duct for alternator cooling duct.
- Release plug-and-socket connections.
- Release hose clip and retaining screws.
- Remove air cleaner with air mass meter.
- Remove Fan.
CAUTION: Left-hand threads. Using special tool 11 5 030, brace against pulley and unfasten cap nut from water pump using special tool 11 5 040.
Installation Note: Tighten fan with special tool 11 5 040. Tightening torque = 40 - 50 Nm (30 - 37 ft lbs).
NOTE: When using special tool 11 5 040, 30 Nm (22 ft lbs) on the torque wrench scale are equivalent to a tightening torque of 40 Nm (30 ft lbs).
- Lift out expanding rivet on left and right.
- Detach fan with fan clutch from water pump and lift upwards together with fan shroud.
- Remove coolant hoses from engine, heating valve (1), and heater (2).
- Disconnect throttle cable (Bowden cable) from throttle valve.
NOTE: This step is necessary to be able to disconnect the engine wiring harness from the engine.
- Pull adapter out of brake booster.
CAUTION: Plug connection bore.
- Take off covers.
NOTE: Lift cover horizontally, pull it forward and then swing it out over oil filler neck.
- Unscrew earth strap at timing-case cover.
- Remove screws (1 and 2).
- Pull off connecting strip.
CAUTION: Watch out for rubber seals.
- Pull off connectors at ignition coils.
- Take off connecting strip complete with wires.
- Unclip connection for cylinder head vent.
- Pull off connector for air-temperature sensor.
- Pull off hose for tank ventilation.
- Disconnect hoses for throttle-valve pre-heating.
- Pull off connector for throttle-valve switch.
CAUTION: Retainer breaks off easily.
- Unclip hose for idle-speed control valve at manifold.
NOTE: Figure shows bottom view of connection. (Not visible in vehicle) In some cars the retainer could be additionally secured by a catch strap.
WARNING: Catch and dispose of fuel as it escapes.
- Unfasten fuel delivery and fuel return lines.
- Follow instructions on removal and installation of fuel hoses.
Installation Note:
(1) Front = intake from filter (blank pipe)
(2) Back = Return (black pipe)
- Remove support from manifold.
- Unfasten intake manifold from cylinder head.
CAUTION: Make sure that no parts fall into ports.
Installation Note: Replace seals.
- Disconnect plug-in connections (1 to 4).
1. Temperature sensor
2. Remote thermometer
3. Oil-pressure switch
4. Idle speed control valve
- Unfasten plug connection.
1. Sensor for cylinder recognition (black)
2. Impulse sensor for DME (grey)
- If installed: Disconnect plug-in connection for VANOS control unit.
- Disconnect wires at alternator.
- Unscrew connections at starter.
- Unscrew cable duct.
- Place engine wiring harness to one side.
Installation Note: The plug and screw connections are described in section on replacing the wiring harness section on the engine, Engine Wiring Harness Arrangement
- Remove power steering pump
- Loosen drive belt:
Insert hexagon key into screw for tensioning wheel. Clamping element is compressed by slow clockwise rotation (1).
- Lift off drive belt.
Installation Note: Note arrangement of drive belt and check for correct position in grooves.
- Unscrew power steering pump from engine and tie back to one side.
NOTE: Lines remain connected.
- Unscrew power-steering oil supply tank from left-hand engine carrier and tie back to one side.
AC Compressor Belt:
- Remove air conditioner compressor
- Loosen drive belt:
- Insert hexagon key into screw for tensioning wheel.
- Rotate slowly clockwise to press together the clamping element.
- Lift off drive belt.
Installation Note: Note arrangement of drive belt and check for correct position in grooves.
- Unscrew and remove air conditioning compressor and tie up to one side.
NOTE: Lines remain connected.
Front and rear suspension arrangement
- Unscrew right-hand engine mount and earthing cable.
- Unscrew left-hand engine mount.
Installation Note: If necessary loosen engine mount from front axle support. Tightening torque:
M8 22 Nm (16 ft lbs).
M10 42 Nm (31 ft lbs).
- Fit engine to special tool 11 0 020.
- Lift out engine
CAUTION: A removed engine with installed HVA (hydraulic valve compensation) elements must not be left upside down for longer than 10 minutes, as otherwise HVA elements will lose hydraulic fluid and no longer function correctly.
- Install in reverse order of removal, paying close attention to installation notes and proper electrical and fuel connections.