Engine: Service and Repair

Note instructions on connecting and decoupling battery, refer to Service Precautions.
Disconnect negative battery lead.





Lift engine hood into assembly position.
Disconnect damper on hood, open hood fully and secure with a screw on left and right sides.





Version 1
(acoustic cover screwed down)
Pry out sealing cap. Unscrew nuts. Remove acoustic cover.





Version 2
(acoustic cover with press-stud fastener)
Open press-studs (1 through 4) one at a time, at the same time lifting the acoustic cover slightly. Once all four press-studs have been opened, remove the acoustic cover.
Installation:
Position acoustic cover and press downwards until press studs (1 through 4) click into place.





Remove connector for brake force booster.





Unfasten main flow oil filter housing from bracket and attach to engine.

Note: Lines remain connected.





Caution: Catch and dispose of fuel as it escapes.

Unfasten fuel feed and return lines to injector tube.
Follow instructions on removal and installation of fuel hoses, refer to Powertrain Management
Remove intake filter housing with mass air flow sensor, refer to Powertrain Management
Remove throttle body ASC+T, refer to Powertrain Management
Disconnect Bowden cables for throttle valve actuation. This operation is described in section on removing and installing/sealing the throttle body, refer to Powertrain Management





Disconnect plug connection (2) and vacuum hose (3) from tank vent valve.
Unfasten engine section of wiring harness and placing to one side with cable ducts.
Unclip diagnosis connector on spring strut shock absorber and place to one side.
Unfasten heat baffle plate on left and right sides.
Unfasten drain plug for coolant in left and right engine block. Drain and dispose of coolant.
Installation:
Replace sealing ring.
Tightening torque, refer to Engine, Specifications.
Remove radiator, refer to Cooling System.
Remove transmission.
Unfasten positive battery lead from starter motor.
Remove starter motor.
Unfasten positive battery lead from oil pan and unfasten left carrier bracket and alternator.





Remove cooling air duct for alternator.
Remove alternator drive belt, refer to Drive Belts, Mounts, Brackets and Accessories.
Remove vane pump, refer to Steering and Suspension.
Remove compressor drive belt from air conditioner, refer to Drive Belts, Mounts, Brackets and Accessories
Disconnect a/c compressor from mounting block and tie up to one side.

Note: Lines remain connected.





Unfasten ground tape from engine support.
Unfasten top left and right nuts on engine mount.





Unfasten coolant hoses from coolant manifold.
Remove left and right exhaust manifolds, refer to Exhaust System.





Caution: Only raise engine on locating lugs provided for this purpose.

Layout of front engine mount.





Layout of rear engine mount.





Secure engine to special tool 11 0 000.

Caution: Note narrow points between lines on ABS unit, air conditioner compressor with lines, cylinder head cover, steering spindle and heating valve.

Carefully lift out engine.





Installation:
E38 (7 Series)
Install engine mount in rear bore (2) of mounting bracket.
E39 (5 Series)
Install engine mount in front bore (1) of support bracket.