BMW 318/325/M3/525/535/M5 1989-1993 Repair Information

Engines

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REMOVAL & INSTALLATION E30 3 Series



WITH M42 ENGINE
  1. Disconnect the battery ground cable. Remove the transmission and remove the engine splash guard. Disconnect the gas spring and prop rod and support hood safely in the fully open position.
  2.  
  3. Remove the fan cowl by turning the expansion rivets on the left and right sides. Life the cowl up and out of the engine compartment.
  4.  
  5. Hold the fan pulley while unscrewing the fan nut counterclockwise to unscrew.
  6.  
  7. Drain the coolant from the engine block. Disconnect the bottom hose from the radiator expansion tank, the engine coolant hoses and the heater hoses from the splash wall. Drain all coolant into clean containers for reuse or proper disposal.
  8.  
  9. Disconnect the air flow meter electrical plug and loosen the hose clamp and mounting screws. Lift the air sensor with the air cleaner up and out of the engine compartment.
  10.  
  11. Unclip the throttle cable and pull the cable out with the rubber holder.
  12.  
  13. Disconnect the fuel lines taking note of their positions. Pull off the vent hose to the filter for tank venting.
  14.  
  15. Disconnect the vacuum fitting at the brake booster.
  16.  
  17. Remove the ignition leads from the coil. Unscrew the connections at the alternator and starter. Disconnect the 2 plugs from the electrical duct. Remove the plug from the throttle valve potentiometer located at the throttle neck. Pull off the tank venting valve plug located next to the air cleaner. Disconnect the fuel injector plug located at the end of the electrical duct near to the fuel pipes. Pull off the idle speed control connector at the rear of the intake manifold. Disconnect the oil pressure switch electrical connection.
  18.  
  19. Unscrew the front and rear intake manifold supports.
  20.  
  21. Remove the electrical duct from the engine. Disconnect the coolant temperature senders for the gauge and the dme.
  22.  
  23. Disconnect the electrical duct and wiring harness on the engine and lay if off to the side of the engine.
  24.  
  25. Use a suitable lifting yoke to attach to the engine lifting eyes. Unscrew the motor mounts and the engine ground strap. Lift out the engine.
  26.  

To install:
  1. Lower engine into engine compartment. Fasten the motor mounts and the ground strap.
  2.  
  3. Attach the engine wiring harness and electrical duct. Make sure that the rubber grommets on the duct are clipped in correctly. Connect the leads to the 2 coolant sensors and the oil pressure switch.
  4.  
  5. Fasten the front and rear intake manifold supports.
  6.  
  7. Connect the idle speed control plug, the fuel injector plug, the tank venting valve plug, the throttle valve potentiometer plug and the electrical lead duct plugs.
  8.  
  9. Reconnect the starter and the alternator. Attach the ignition leads to the coil in the proper order.
  10.  
  11. Refit the vacuum connection to the brake booster. Reconnect the tank vent hose and the fuel hoses. The upper fuel hose is the return line and the bottom is the feed line.
  12.  
  13. Attach the throttle cable and its holder. Replace the air cleaner and air flow meter assembly. Attach the electrical connector to the air flow meter.
  14.  
  15. Connect the heater hoses, engine coolant hoses and the radiator expansion tank hose.
  16.  
  17. Install the fan using tool 11 5 040 or equivalent. Torque the nut to 29 ft. lbs. (40 Nm). If using the tool set the torque wrench to 22 ft. lbs. (30 Nm); the additional length of the tool multiples the torque to achieve 29 ft. lbs. (40 Nm) at the nut.
  18.  
  19. replace the fan cowl taking care to engage the tabs at the right and left.
  20.  
  21. Replace the splash guard and the transmission. Reconnect the hood prop rod and gas spring.
  22.  
  23. Add the proper coolant mixture and bleed the cooling system.
  24.  
  25. Connect the battery leads and check all fluid levels before starting the engine.
  26.  

WITH S14 ENGINE

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Air conditioner compressor mounting bolts on the S14 engine

  1. Disconnect the negative battery cable. Remove the transmission.
  2.  
  3. Remove the splash guard from underneath the engine. Put a drain pan underneath and then drain coolant from both the radiator and block.
  4.  
  5. Loosen the hose clamps at either end of the air intake hose leading to the air intake sensor. Pull off the hose. Then, pull both electrical connectors off the air cleaner/airflow sensor unit. Remove both mounting nuts and remove the unit.
  6.  
  7. Disconnect the accelerator and cruise control cables. Unscrew the nuts mounting the cable housing mounting bracket and set the housings and bracket aside.
  8.  
  9. Loosen the clamp and disconnect the brake booster vacuum hose.
  10.  
  11. Loosen the clamp and disconnect the other end of the booster vacuum hose at the manifold. Remove the nut from the intake manifold brace.
  12.  
  13. Loosen the hose clamp and disconnect the air intake hose at the manifold. Then, remove all the nuts attaching the manifold assembly to the outer ends of the intake throttle necks and remove the assembly.
  14.  
  15. Put a drain pan underneath and then loosen the hose clamps and disconnect the coolant expansion tank hoses. Disconnect the engine ground strap.
  16.  
  17. Disconnect the ignition coil high tension lead. Then, label and disconnect the plugs on the front of the block. Remove the nut fastening another lead farther forward of the plugs and move the lead aside so it will not interfere with engine removal.
  18.  
  19. Label and disconnect the plugs from the rear of the alternator. Label the additional leads and then remove the nuts and disconnect those leads. It's best to reinstall nuts once the leads are removed to keep them from being mixed up.
  20.  
  21. Remove the cover for the electrical connectors from the starter. Label the leads and then remove the attaching nuts and disconnect them. Reinstall the nuts.
  22.  
  23. There is a wire running to a connector on the oil pan to warn of low oil level. Pull off the connector, unscrew the carrier for the lead; and then pull the lead out from above. Pull off the connectors near where the lead for the low oil warning system ran and unclip the wires from the carrier.
  24.  
  25. Find the vacuum hose leading to the fuel pressure regulator. Pull it off. Label and then disconnect the plugs. Unscrew the mounting screw for the electrical lead connecting with the top of the block and remove the lead and its carrier.
  26.  
  27. There is a vacuum hose connecting with one of the throttle necks. Disconnect it and pull it out of the intake manifold bracket. Pull off the electrical connector. Pull out the rubber retainer, and then pull the idle speed control out and put it aside. The engine wiring harness is located nearby. Take it out of its carriers.
  28.  
  29. All the fuel injectors are plugged into a common plate. Carefully and evenly pull the plate off the injectors, pull it out past the pressure regulator, and lay it aside.
  30.  
  31. Loosen the clamp and then disconnect the pcv hose. Label and then disconnect the fuel lines connecting the injector circuit. Put a drain pan underneath and then disconnect the heater hose from the cylinder head.
  32.  
  33. Loosen the clamp near the throttle necks and then pull the engine wiring harness out and put it aside. Put a drain pan underneath and then disconnect the heater hose that connects to the block.
  34.  
  35. Loosen the mounting clamp for the carbon canister, slide it out of the clamp, and place it aside with the hoses still connected.
  36.  
  37. Note the routing of the oil cooler liens where they connect at the base of the oil filter. Label them if necessary. Put a drain pan underneath and then unscrew the flared connectors for the lines.
  38.  
  39. Unbolt and remove the fan. Store it in an upright position. Remove the radiator.
  40.  
  41. Support the power steering pump. Remove the adjusting bolt and disconnect and remove the belt. Then, remove the nuts and bolts on which the unit hinges. Pull the unit aside and hang it so there will not be strain on the hoses.
  42.  
  43. Remove the adjusting bolt for the air conditioning compressor and disconnect and remove the belt. Them, remove the nut at one end of the hinge bolt and pull the bolt out, suspending the compressor.
  44.  
  45. Remove the through-bolts to disconnect the engine hood supports and then open the hood and support it securely.
  46.  
  47. Suspend the engine with a suitable lifting device. Then, remove the nuts for the engine mounting bolts. The mounts are on the axle carrier and the nut is at the top on the left and on the bottom on the right. Then, carefully lift the engine out of the compartment, avoiding between it and the components remaining in the vehicle.
  48.  

To install:
  1. Keep these points in mind during installation:
    1. Torque the engine mounting bolts to 32.5 ft. lbs. (44 Nm).
    2.  
    3. Adjust the belt tension for the air conditioning compressor and power steering pump drive belts to give 1 / 2 - 3 / 4 inch deflection.
    4.  
    5. Torque the oil cooler line flare nuts to 25 ft. lbs. (34 Nm).
    6.  
    7. When reconnecting the intake manifold to the throttle necks, inspect and, if necessary, replace the O-rings. Torque the mounting nuts to 6.5 ft. lbs. (9 Nm).
    8.  

  2.  
  3. Reverse the procedures used for removal and lower the engine into the engine compartment. When the engine is positioned, the guide pin must fit in the bore of the axle carrier. Torque the mounting bolts on the front axle carrier (small bolt) to 18-20 ft. lbs. (25-27 Nm); the larger bolt to 31-35 ft. lbs. (40-47 Nm). The mount-to-bracket bolts are torqued to 31-35 ft. lbs. (40-47 Nm).
  4.  
  5. Install the intake manifold assembly and connect the fuel liens, use new hose clamps to connect the fuel lines to fuel filter. Connect all of the multi-prong plugs and all vacuum hoses.
  6.  
  7. Connect the accelerator cable and cruise control cable to the throttle body and adjust the accelerator cable and cruise control cable.
  8.  
  9. Install the coolant recovery tank, use a new hose clamp on the coolant expansion tank.
  10.  
  11. Install the air cleaner and reconnect all electrical plugs. Connect and install the relays in the relay box.
  12.  
  13. Reconnect the wiring to the main control unit and install the idle control unit.
  14.  
  15. Install the air conditioning compressor and power steering pump, properly route the accessory drive belt. Adjust the belt tension.
  16.  
  17. Install the radiator and connect the hoses.
  18.  
  19. Install the transmission.
  20.  
  21. Install the hood support and lower the hood.
  22.  
  23. Make sure all fluid levels are correct before starting the engine. Bleed air from the cooling system.
  24.  

WITH M20 ENGINES
  1. Disconnect the negative battery cable. Remove the transmission.
  2.  
  3. Without disconnecting hoses, loosen and remove the power steering pump bolts and remove the pump and belts and support the pump out of the way.
  4.  
  5. Remove the drain plug and remove the coolant from the radiator. Then, remove the radiator. Unbolt and remove the fan from the engine. Store it in an upright position.
  6.  
  7. Without disconnecting hoses, remove the mounting bolts that run through the compressor body and remove the air conditioner compressor and drive belt and support the compressor out of the way.
  8.  
  9. Remove the through-bolts to disconnect the engine hood supports and then open the hood and support it securely.
  10.  

The hood must be propped in a secure manner. If it falls during work serious injury could result.

  1. Disconnect the accelerator cable. If the vehicle has cruise control, disconnect the cruise control cable. If the vehicle has an automatic transmission, disconnect the throttle cable leading to the transmission.
  2.  
  3. Pull the large, multi-prong plug off the airflow sensor (an integral part of the air cleaner). Loosen the clamp and disconne4ct the air intake hose at the airflow sensor. Remove the mounting nuts and remove the air cleaner/airflow sensor unit.
  4.  
  5. Disconnect the coolant expansion tank hose. Disconnect the large, multi-prong connector near the air intake hose.
  6.  
  7. The diagnosis plug is a large, screw-on connector located near the thermostat and associated hoses. Unscrew and disconnect this connector.
  8.  
  9. Disconnect the large coolant hoses connecting to the thermostat.
  10.  
  11. Make sure the engine is cold. Place a metal container under the connection to collect fuel; then, disconnect the fuel line at the connection right near the thermostat housing by unscrewing it. Unfasten the fuel line clip about a foot away from this connection.
  12.  
  13. Disconnect the electrical plugs near the diagnosis plug connector. Disconnect the bracket for the dipstick guide tube.
  14.  
  15. Remove the bolts which attach the water pipes going to the engine to mounting brackets.
  16.  
  17. Disconnect the heater hoses at the heater core (near the firewall). Remove the coolant hose running to the top of the block.
  18.  
  19. Place a metal a metal container under the connection to collect fuel; then, disconnect the remaining fuel hose supplying the engine injectors. Disconnect the electrical connectors.
  20.  
  21. Remove the bolt from the mounting brace connecting with the cylinder head.
  22.  
  23. Mark and then disconnect the electrical leads from the starter. Unbolt the starter and lift it out from above.
  24.  
  25. Place a metal container under the connection to collect fuel; then, disconnect the fuel pipe that runs right near the starter.
  26.  
  27. Label electrical connectors on the alternator. Then, pull off the rubber caps for the connectors which are attached with nuts and remove the nuts and any washers. Disconnect the plug-on connector.
  28.  
  29. Disconnect the electrical leads for the coil. Loosen the clips attaching the leads under the distributor and pull the harness away to the left. Disconnect the oil pressure sending unit.
  30.  
  31. Place a drain pan underneath the connections and then disconnect the oil cooler pipes at the crankcase by unscrewing the flare nut fittings.
  32.  
  33. Take the cover off the relay box. Then, lift out the relays and their mounting sockets. Place the relays and associated wiring on top of the engine so they will come out with it.
  34.  
  35. Loosen the mounting clamp and then remove the carbon canister. There is a plate to which a number of electrical leads are connected. Remove the mounting screws and move the plate aside so it will clear the dipstick guide tube when the engine is removed.
  36.  
  37. Remove the 2 bolts that fasten the wiring harness to the firewall. Them, disconnect the engine ground strap.
  38.  
  39. Remove both engine mount through-bolts. Lift out the engine with a suitable hoist, using hooks at front and rear.
  40.  

To install:
  1. Reverse the procedures used for removal and lower the engine into the engine compartment. When the engine is positioned, the guide pin must fit in the bore of the axle carrier. Torque the mounting bolts on the front axle carrier (small bolt) to 18-20 ft. lbs. (25-27 Nm); the larger bolt to 31-35. The mount-to-bracket bolts are torqued to (small bolt) 16-17 ft. lbs. (22-23 Nm); (large bolt) 31-35 ft. lbs. (40-47 Nm).
  2.  
  3. Connect the fuel lines, use new hose clamps to connect the fuel lines to the fuel filter. Connect all of the multi-prong plugs and all vacuum hoses.
  4.  
  5. Connect the accelerator cable and cruise control cable to the throttle body and adjust the accelerator cable and cruise control cable.
  6.  
  7. Install the coolant recovery tank, use a new hose clamp on the coolant expansion tank.
  8.  
  9. Install the air cleaner and reconnect all electrical plugs. Connect and install the relays in the relay box.
  10.  
  11. Reconnect the wiring to the main control unit and install the idle control unit.
  12.  
  13. Install the air conditioning compressor and power steering pump, properly route the accessory drive belt. Adjust the belt tension.
  14.  
  15. Install the radiator and connect the hoses.
  16.  
  17. Install the transmission.
  18.  
  19. Install the hood support.
  20.  
  21. Make sure all fluid levels are correct before starting the engine. Bleed air from the cooling system.
  22.  

E36 3 Series

WITH M42 ENGINE
  1. Disconnect the battery ground cable. Remove the transmission and remove the engine splash guard. Press the hinge so it goes over center and support hood safely in the fully open position.
  2.  
  3. Remove the fan cowl by turning the expansion rivets on the left and right sides. Lift the cowl up and out of the engine compartment. Disconnect the air conditioner compressor without removing the liens. Suspend of to one side.
  4.  
  5. Hold the fan pulley while unscrewing the fan nut from the shaft. The shaft uses left hand threads; turn the nut counterclockwise to unscrew.
  6.  
  7. Drain the coolant from the engine block. Disconnect the bottom hose from the radiator expansion tank, the engine coolant hoses and the heater hoses from the splash wall. Drain all coolant into clean containers for reuse or proper disposal.
  8.  
  9. Disconnect the air flow meter electrical plug and loosen the hose clamp and mounting screws. Lift the air sensor with the air cleaner up and out of the engine compartment.
  10.  
  11. Remove the air intake duct and disconnect the idle speed control hose. Disconnect the wire holders from the duct.
  12.  
  13. Unbolt the power steering reservoir. Unbolt the power steering pump and support without tension on the hose. Secure the power steering reservoir off to the side.
  14.  
  15. Flip up the throttle linkage cover on the throttle body. Unscrew the holder and disconnect the cable from the linkage.
  16.  
  17. Mark the locations of the fuel feed and return hoses. The upper hose is the return line. Disconnect the hoses and plug.
  18.  

Disconnect the vacuum line from the brake booster. Plug the opening to prevent dirt from entering.

  1. Remove the grill from the air intake cowl at the base of the windshield. Remove the electrical lead tray. Remove the screws on the right side cowl holder bracket and the screw on the left side. Remove the cowl from the engine compartment.
  2.  
  3. Remove the ignition leads from the spark plugs. Disconnect the wiring from the alternator and the starter. Disconnect the cylinder id sensor and the pulse sender located just behind the oil filter housing. Disconnect the idle speed control and remove from the holder.
  4.  
  5. Disconnect the throttle position sensor lead, oil pressure sender and the tank venting valve connector. Unbolt the fuel line holder and the intake manifold support. Loosen the clamp holding the pipe to the intake support.
  6.  
  7. Unscrew the intake support from the electrical lead duct. Disconnect the temperature sensors under the intake manifold. Unplug the fuel injectors and disconnect the electric lead duct from the engine. Place off to the side.
  8.  
  9. Disconnect the coolant the coolant hose from the transfer pipe on the side of the engine.
  10.  
  11. Connect an engine lifting yoke to the lifting tabs at the front and rear of the engine. Disconnect the ground strap and motor mounts. Remove the engine.
  12.  

Do not invert the engine for longer than 10 minutes total or the hydraulic valve lash compensators will drain. This will render the compensators useless and will require replacement.

To install:
  1. Install the engine in the car. Connect the ground strap and torque the engine mounts to 30 ft. lbs, (42 Nm).
  2.  
  3. Connect the coolant hose to the transfer pipe. Replace the injector electrical lead duct and connect the injectors. Replace the electric lead duct on the intake support and replace the intake support. Connect the temperature sensors under the intake manifold. Attach the fuel lien holder.
  4.  
  5. Connect the tank venting valve, the throttle position sender, the oil pressure switch and the idle speed control. Install the idle speed control in its holder. Connect the cylinder id sender and the pulse sender. Connect the starter and alternator. Connect the ignition leads.
  6.  
  7. Install the air cowl, bracket and grill. Connect the brake booster vacuum line and the fuel hoses. The upper hose is the fuel return line. Connect the throttle cable and holder.
  8.  
  9. Install the power steering pump and reservoir. Install the air intake duct and the air cleaner assembly. Connect the idle speed lien and the electrical leads. Connect the air flow sensor.
  10.  
  11. Connect the coolant hoses. Install the fan, fan cowl and the air conditioner compressor. Install the hood and transmission. Install the splash guard and fill the engine fluids.
  12.  
  13. Connect the battery, start the car, bleed the coolant and check for leaks.
  14.  

WITH M50 ENGINE

See Figure 2

Click image to see an enlarged view

Fig. Fig. 2: Engine mount and exhaust flanges on M50 engine installed in the E36 chassis

  1. Disconnect the air mass sensor plug and loosen the air intake duct hose clamp. Remove the air cleaner assembly. Disconnect the hoses for the idle speed control and the crankcase breather.
  2.  
  3. Unscrew and remove the ducting for the alternator. Pull out the fan cowl expansion rivets and remove the cowl upwards. Hold the pulley with tool 11 5 030 or equivalent, and unscrew the fan clockwise. Remove the fan and keep upright.
  4.  
  5. Drain the coolant from the block at the plug accessible through the exhaust manifold. Remove the upper and lower radiator hoses from the radiator. Disconnect the coolant level switch and the automatic transmission cooler lines. Plug the cooler lines. Disconnect the right side hose and the temperature sensor.
  6.  
  7. Insert a tool into the radiator support clips and press down on the tab. Pull back on the radiator to release it. Remove the radiator. Disconnect the heater hoses from the heater and heater valve.
  8.  
  9. Remove the grill from the intake cowl at the base of the windshield. Remove the electrical lead tray. Remove the screws on the right side cowl holder bracket and the screw on the left side. Remove the cowl from the engine compartment.
  10.  
  11. Unscrew the fastener from the throttle cable cover and pull the cover forward and off. Unclip the cable and pull the cable out with the rubber holder.
  12.  
  13. Pull the vacuum fitting from the brake booster and plug the openings.
  14.  
  15. Remove the engine and intake manifold covers. Unscrew the bolt holding the ground strap on the front lifting eye. Replace the bolt before lifting the engine.
  16.  
  17. Unscrew the 2 bolts holding the plug plate and pull off the plug plate. Be careful not to damage the rubber seals. Take off the ignition coil electrical plugs. Remove the plug plate complete with the electrical leads.
  18.  
  19. Remove the cylinder head vent hose and pull off the air temperature sensor plug. Remove the tank venting hose and the throttle heating hoses from the throttle body. Remove the throttle valve switch plug. Unclip the idle speed control valve mounted on the manifold. Disconnect the fuel hoses from the pipes.
  20.  
  21. Unscrew the hardware holding the intake manifold to the cylinder head. Remove the intake manifold taking care not to drop anything into the exposed ports.
  22.  
  23. Disconnect the plugs from the temperature sensor, temperature gauge, the oil pressure switch and the idle speed control valve. Disconnect the cylinder identifying sender plug (black) and the pulse sender plug (gray) for the dme. Unscrew the oxygen sensor plug in the holder.
  24.  
  25. Remove the electric leads from the alternator and the starter. Unscrew the electrical lead tray and place the engine wiring harness to the side.
  26.  
  27. Loosen the drive belt for the power steering pump and the air conditioner compressor by turning their respective tensioners clockwise. This will release the tension on the belt and allow the belt to be removed.
  28.  
  29. Unbolt the power steering pump and place to the side without disconnecting the hoses. Unbolt the air conditioner compressor and place to the side without disconnecting the lines.
  30.  
  31. Attach a lifting fixture to the engine lifting hooks. Unscrew the engine mounts and ground strap. Lift the engine out of the vehicle being careful of the front radiator mount.
  32.  

To install:
  1. Lower the engine into the vehicle and attach the motor mounts and ground strap.
  2.  
  3. Install the power steering pump and the air conditioner compressor. Install the drive belts.
  4.  
  5. Replace the wiring harness and electrical lead tray on the engine. Connect the leads to the starter and alternator. Screw in the plug for the oxygen sensor holder. Connect the leads for the cylinder identifying sender, the dme pulse sender, the temperature sensor, the temperature gauge sender, the oil pressure switch and the idle speed control valve.
  6.  
  7. Install the intake manifold making sure that the intake seals are intact. Replace the intake seals if any signs of deterioration are evident.
  8.  
  9. Attach the fuel lines. The upper line is the return and the lower is the feed.
  10.  
  11. Attach the idle speed control valve hose located on the manifold.
  12.  
  13. Connect the throttle valve switch plug, the throttle valve heating lines and the tank vent line.
  14.  
  15. Connect the air temperature sensor plug and the attach the cylinder head venting hoses.
  16.  
  17. Reconnect the plugs for the ignition coils and mount the plug plate. Attach the ground strap to the front lifting eye.
  18.  
  19. Replace the engine and manifold covers. Connect the line to the brake booster.
  20.  
  21. Reconnect the throttle cable and cover. Install the air intake cowl at the base of the windshield.
  22.  
  23. Connect the heater hoses to the valve and inlet. Remount the radiator by pressing down on the mounting clips to fasten. Check that the lower mounts are in place. Connect the temperature switch plug for the air conditioner and replace the trim panel. Connect the cooling system hoses and the automatic transmission lines. Use new seals on the transmission lines and tighten to 13-15 ft. lbs. (18-21 Nm). Make sure the block coolant plug is in place and tight.
  24.  
  25. Install the fan using tool 11 5 040 or equivalent wrench and holding too 11 5 030 or equivalent. Torque the nut to 29 ft. lbs. (40 Nm). If using the tool set the torque wrench to 22 ft. lbs. (30 Nm); the additional length of the tool multiplies the torque to achieve 29 ft. lbs. (40 Nm) at the nut. Replace the radiator cowling into its mounting slots and press in the rivets.
  26.  
  27. Install the alternator air ducting. Connect the idle speed and crankcase breather hose to the air intake duct. Replace the air cleaner assembly and connect the electrical plug.
  28.  
  29. Install the transmission and fill and bleed the cooling system. Connect the battery and install the splash shield. Check all fluids before starting engine.
  30.  

5 Series

WITH M20 ENGINE
  1. Allow the engine to cool. Disconnect the battery cable from the battery, negative side first. Open the hood to the widest position possible and secure in place.
  2.  
  3. Remove the splash shield from under the car. Drain the coolant and remove the fan and radiator.
  4.  
  5. Remove the transmission.
  6.  
  7. Disconnect the throttle cable and the cruise control cable. Disconnect the cable brackets from the intake manifold.
  8.  
  9. Loosen and remove the electrical and air connections to the air cleaner assembly. Remove the air cleaner assembly and air flow meter.
  10.  
  11. Disconnect the coolant hoses from the engine. Mark the feed and return fuel line connections. Remove the fuel lines, catching any excess fuel.
  12.  
  13. Disconnect the idle speed control. Remove the brake booster vacuum line and plug the opening.
  14.  
  15. Disconnect the heater hoses and the vacuum line going into the passenger compartment. Disconnect the heater coolant pipe.
  16.  
  17. Disconnect the leads from the ignition coil and the oil pressure switch. Place the electrical lead duct from under the distributor to the left side of the engine.
  18.  
  19. If equipped, disconnect the oil cooler lines from the engine and place to the side. Plug the lines to prevent oil from leaking out and to keep any contaminants from inside the lines.
  20.  
  21. Disconnect the starter and the alternator. Disconnect the plug located behind the alternator.
  22.  
  23. Disconnect the dme sensors and the other engine sensors. Disconnect the engine harness and place off to the side.
  24.  
  25. Disconnect the ground strap. Connect an engine lifting sling to the engine.
  26.  
  27. Disconnect the left engine mount from above and the right side mount from under the car. Lift the engine out of the car.
  28.  

To install:
  1. Install the engine and tighten the motor mounts to 32.5 ft. lbs. (45 Nm). Install the ground strap.
  2.  
  3. Install the engine wiring harness and connect the sensors and hoses. Connect the dme sensors. Connect the alternator and starter. Connect the plug located behind the alternator.
  4.  
  5. Install the oil cooler lines, if equipped. Tighten to 22-29 ft. lbs. (30-40 Nm).
  6.  
  7. Connect the ignition coil. Connect the coolant lines and pipes. Connect the vacuum line going into the passenger compartment.
  8.  
  9. Install the idle speed control and the brake booster vacuum line. Connect the radiator hoses and the fuel lines to the previously marked locations.
  10.  
  11. Install the air cleaner and the air flow meter. Connect the air ducts and the electrical connections.
  12.  
  13. Install the throttle cables and the bracket. Install the air conditioner compressor and the power steering pump. Tension the belts.
  14.  
  15. Install the radiator and connect the hoses.
  16.  
  17. Install the transmission.
  18.  
  19. Install the hood support.
  20.  
  21. Make sure all fluid levels are correct before starting the engine. Bleed air from the cooling system.
  22.  

WITH M50 ENGINE
  1. Disconnect the battery terminals, negative side first, and remove the battery, if mounted in engine compartment. Unscrew and remove the battery tray. Remove the transmission.
  2.  
  3. Loosen the clamp on the cooling duct to the alternator and remove the duct.
  4.  
  5. Disconnect the plug to the air flow meter and loosen the clamps to the air cleaner duct. Unscrew the mounting bolts and remove the air cleaner assembly.
  6.  
  7. Pull out the expansion rivets that hold the fan cowl. Remove the cowl by pulling up out of the engine compartment.
  8.  
  9. Hold the fan pulley while unscrewing the fan nut from the shaft. The shaft uses left hand threads; turn the nut counterclockwise to unscrew.
  10.  
  11. Drain the coolant from the block. The drain plug is located between the exhaust manifolds. Disconnect the coolant hoses from the radiator and remove the coolant level switch plug. On automatic transmission equipped vehicles remove the oil lines to the radiator and plug.
  12.  
  13. Disconnect the bottom radiator hose and remove the trim panel from the right side of the engine compartment to expose the side of the radiator and the air conditioner condenser.
  14.  
  15. Pull the plug off of the air conditioner temperature switch.
  16.  
  17. Remove the radiator supporting clips by inserting a small prybar down from above into the slot and pulling back. Pull the radiator free from the clip. Remove the radiator from the vehicle.
  18.  
  19. Disconnect the heater hoses from the heater valve and the heater.
  20.  
  21. Unscrew the fastener from the throttle cable cover and pull the cover forward and off. Unclip the cable and pull the cable out with the rubber holder.
  22.  
  23. Pull the vacuum fitting from the brake booster and plug the openings.
  24.  
  25. Remove the engine and intake manifold covers. Unscrew the bolt holding the ground strap on the front lifting eye. Replace the bolt before lifting the engine.
  26.  
  27. Unscrew the 2 bolts holding the plug plate and pull off the plug plate. Be careful not to damage the rubber seals. Take off the ignition coil electrical plugs. Remove the plug plate complete with the electrical leads.
  28.  
  29. Remove the cylinder head vent hose and pull off the air temperature sensor plug. Remove the tank venting hose and the throttle heating hoses from the throttle body. Remove the throttle valve switch plug. Unclip the idle speed control valve mounted on the manifold. Disconnect the fuel hoses from the pipes.
  30.  
  31. Unscrew the hardware holding the intake manifold to the cylinder head. Remove the intake manifold taking care not to drop anything into the exposed ports.
  32.  
  33. Disconnect the plugs from the temperature sensor, temperature gauge, the oil pressure switch and the idle speed control valve. Disconnect the cylinder identifying sender plug (black) and the pulse sender plug (gray) for the dme. Unscrew the oxygen sensor plug in the holder.
  34.  
  35. Remove the electric leads from the alternator and the starter. Unscrew the electrical lead tray and place the engine wiring harness to the side.
  36.  
  37. Loosen the drive belt for the power steering pump and the air conditioner compressor by turning their respective tensioners clockwise. This will release the tension on the belt and allow the belt to be removed.
  38.  
  39. Unbolt the power steering pump and place to the side without disconnecting the hoses. Unbolt the air conditioner compressor and place to the side without disconnecting the lines.
  40.  
  41. Attach a lifting fixture to the engine lifting hooks. Unscrew the engine mounts and ground strap. Lift the engine out of the vehicle being careful of the front radiator mount.
  42.  

To install:
  1. Lower the engine into the vehicle and attach the motor mounts and ground strap.
  2.  
  3. Install the power steering pump and the air conditioner compressor. Install the drive belts.
  4.  
  5. Replace the wiring harness and electrical lead tray on the engine. Connect the leads to the starter and alternator. Screw in the plug for the oxygen sensor holder. Connect the leads for the cylinder identifying sender, the dme pulse sender, the temperature sensor, the temperature gauge sender, the oil pressure switch and the idle speed control valve.
  6.  
  7. Install the intake manifold making sure that the intake seals are intact. Replace the intake seals if any signs of deterioration are evident.
  8.  
  9. Attach the fuel lines. The upper line is the return and the lower is the feed.
  10.  
  11. Attach the idle speed control valve hose located on the manifold.
  12.  
  13. Connect the throttle valve switch plug, the throttle valve heating lines and the tank vent line.
  14.  
  15. Connect the air temperature sensor plug and attach the cylinder head venting hoses.
  16.  
  17. Reconnect the plugs for the ignition coils and mount the plug plate. Attach the ground strap to the front lifting eye.
  18.  
  19. Replace the engine and manifold covers. Connect the line to the brake booster.
  20.  
  21. Reconnect the throttle cable and cover.
  22.  
  23. Connect the heater hoses to the valve and inlet. Remount the radiator by pressing down on the mounting clips to fasten. Check that the lower mounts are in place. Connect the temperature switch plug for the air conditioner and replace the trim panel. Connect the cooling system hoses and the automatic transmission lines.
  24.  
  25. Install the fan using tool 11 5 040 or equivalent. Torque the nut to 29 ft. lbs. (40 Nm). If using the tool set the torque wrench to 22 ft. lbs. (30 Nm); the additional length of the tool multiplies the torque to achieve 29 ft. lbs. (40 Nm) at the nut. Replace the radiator cowling.
  26.  
  27. Replace the air cleaner assembly and connect the electrical plug. Install the transmission and fill and bleed the cooling system. Install the battery tray and battery. Check all fluids before starting engine.
  28.  

WITH M30 ENGINE
  1. Allow the engine to cool. Disconnect the battery cable from the battery, negative side first. Open the hood to the widest position possible and secure in place.
  2.  
  3. Remove the splash shield from under the car. Drain the coolant and remove the radiator.
  4.  
  5. Remove the transmission.
  6.  
  7. Remove the nut holding the transmission oil cooler lines to the engine oil pan.
  8.  
  9. Loosen and remove the drive belts to the power steering pump and the air conditioner compressor. Remove the bolts holding the pump and compressor to the engine and remove them from the engine, keeping the lines connected. Wire the pump and compressor out of the way and without any tension on the hoses.
  10.  
  11. Disconnect the hoses from the coolant expansion tank. Remove the screws on the side of the expansion tank and remove the expansion tank from the engine compartment.
  12.  
  13. Disconnect the heater hoses from the heater control valve and the heater inlet pipe.
  14.  
  15. Pull off the connections to the ignition coil. Remove the air cleaner assembly. Disconnect and remove the idle speed control from the intake duct.
  16.  
  17. Disconnect the harness to the air flow meter. Disconnect the ducting to the air flow meter and remove along with the crankcase breather vacuum line.
  18.  
  19. On non-asc equipped cars, disconnect the cruise control cable and the throttle cable at the throttle. Remove the cable mounting bracket. If equipped with asc, remove the connector to the throttle control unit as there will be no throttle cable to disconnect.
  20.  
  21. Disconnect the leads to the starter. Disconnect the 2 electrical connectors in the starter area. Disconnect the oil level sender leads and the alternator connections. Remove the air duct to the alternator.
  22.  
  23. Disconnect the tank venting valve and the hose to the carbon canister.
  24.  
  25. Mark the feed and return fuel lines. Disconnect the lines and catch any spilled fuel.
  26.  
  27. Disconnect the vacuum line from the brake booster and plug the opening. Disconnect the harness connections to the temperature sensors and dme sensors.
  28.  
  29. Disconnect the ground strap and make a check for any remaining lines or electrical leads still attached.
  30.  
  31. Attach a lifting sling to the engine. Remove the engine mount nuts and bolts and lift the engine from the engine bay.
  32.  

To install:
  1. Install the engine into the engine compartment. Torque the engine mounts to 32.5 ft. lbs. (45 Nm). Connect the ground strap.
  2.  
  3. Connect the brake booster vacuum line, the temperature sensors and the dme sensors.
  4.  
  5. Connect the fuel lines to the proper locations as previously marked. Connect the tank venting valve and the carbon canister line. Attach the alternator leads and the cooling duct.
  6.  
  7. Connect the starter leads and the electrical connector in the starter area. Connect the oil level sender leads.
  8.  
  9. Connect the throttle cable and the cruise control cable and bracket. Install the air flow sensor and the crankcase breather line.
  10.  
  11. Install the idle speed control to the air intake duct. Install the air cleaner assembly.
  12.  
  13. Connect the heater lines to the heater control valve and the heater inlet pipe. Install the coolant expansion tank and connect the lines.
  14.  
  15. Install the air conditioner compressor and power steering pump. Adjust the belt tensions.
  16.  
  17. Connect the automatic transmission oil cooling lines to the bracket on the engine oil pan.
  18.  
  19. Install the transmission and the radiator. Fill the cooling system and check the engine fluids. Install the splash shield and connect the battery.
  20.  
  21. Run the engine and check for leaks. Bleed the cooling system.
  22.  

WITH S38 ENGINE

If the engine is to be disassembled the vibration damper nut must be removed from the engine before the engine is removed. This is due to the fact the nut is torqued to approximately 578 ft. lbs. (800 nm) and is almost impossible to remove once the engine has been removed from the engine compartment.

  1. Disconnect the battery negative cable. Then, disconnect the positive cable. Remove the windshield washer jets from the hood and place off to the side. Scribe matchmarks and then remove the hood.
  2.  
  3. Remove the transmission with tool 23 1 330 or equivalent.
  4.  
  5. Remove the radiator along with the oil cooler and fan cowling. Remove the fan by using tool 11 5 030, or equivalent to hold the pulley stationary while unscrewing the lefthand threads of the fan with tool 11 5 040 or equivalent.
  6.  
  7. Remove the alternator cooling duct.
  8.  
  9. Support the power steering pump. Remove the mounting bolts and then hang the pump out of the way in a position that will not put stress on the hoses.
  10.  
  11. Support the air conditioning compressor. Remove the mounting bolts and then hang the compressor out of the way in a position that will not put stress on the hoses.
  12.  
  13. If the engine is going to be disassembled and the vibration damper must be removed, turn the engine so the tdc mark on the tooth wheel faces straight down. Attach tool 11 2 240, or equivalent to the pulley with all 8 of the 8 - 20mm bolts. The mounting pattern is asymmetrical and the tool can only be mounted one way. The tool is designed so it bears against the right side of the subframe and provide the counteroffers to the removal torque of the vibration damper bolt.
  14.  
  15. Disconnect the ground strap and the engine mounts.
  16.  
  17. Remove the headlight cover piece and disconnect the harness from the air cleaner and air flow meter assembly. Remove the mounting hardware and the air ducts. Disconnect the air temperature sensor. Remove the air cleaner and air flow meter assembly.
  18.  
  19. Disconnect the throttle cables and the holder brackets.
  20.  
  21. Disconnect the coolant lines at the coolant expansion tank. Remove the coolant expansion tank. Disconnect the heater coolant hoses at the heater inlet and the heater control valve.
  22.  
  23. Tilt the engine as far forward as possible and support with a wooden block. Disconnect the brake booster vacuum line and plug the opening.
  24.  
  25. Disconnect the air pump intake hose at the air cleaner.
  26.  
  27. Mark the fuel feed and return lines. Disconnect the fuel lines and the tank venting valves located near the base of the engine oil dipstick.
  28.  
  29. Disconnect the starter leads at the remote positive terminal. Lift of the cover directly behind the remote positive terminal. Remove the electric lead covers along the top of the engine and at the rear of the engine compartment. Remove the electronics box cover screw and cover.
  30.  
  31. Mark and disconnect the leads from the ignition coil. Disconnect the ground lead behind the ignition coil. Disconnect the engine electric harness from the holders and disconnect the dme and the 2 multi-pin connectors in the electronic box.
  32.  
  33. Remove the 3 relays still connected to the sockets in the electronics box. Disconnect the connectors and the temperature sensor. Remove the relay holder and the control unit located beneath it. Remove the plug.
  34.  
  35. Remove the grommet holder and pull the harness out with the grommet. Place the harness that will stay with the car and not come out with the engine up on the firewall and secure.
  36.  
  37. Disconnect the engine plug and the diagnosis connector. Remove the holder and place the wiring harness out of the way after loosening the straps.
  38.  
  39. Attach an engine lifting sling. The rear chain should be placed between the intake and the check valve. Lift the engine out of the engine compartment.
  40.  

To install:
  1. Install the engine in the engine compartment and tilt as far forward as possible and block into place. Install the wiring harness into the original positions and secure. Install the diagnostic socket and the engine plug.
  2.  
  3. Install the harness, control unit and the rubber grommet back into the electronics box. Install the grommet holder and the relay holder. Connect the multi-pin connector and the temperature sensor. Connect the positive lead.
  4.  
  5. Connect the ignition coil and the ground strap. Install the cover on the electronics box and in the engine compartment.
  6.  
  7. Connect the tank venting valve at the base of the oil dipstick. Connect the fuel lines to the original positions. Connect the air pump inlet hose to the air cleaner.
  8.  
  9. Connect the vacuum line to the brake booster. Tilt the engine back to the original position. Connect the heater hoses and install the coolant expansion tank.
  10.  
  11. Connect the throttle cables. Install the air cleaner assembly and the air flow meter. Connect the air temperature sensor.
  12.  
  13. Tighten the motor mounts to 30 ft. lbs. (42 Nm). Connect the ground strap.
  14.  
  15. Install the air conditioning compressor and the power steering pump. Tension the belts. Install the alternator cooling duct.
  16.  
  17. Install the fan with tool 11 5 040 or equivalent, and tighten to 29 ft. lbs. (40 Nm). Set the torque wrench to 22 ft. lbs. (30 Nm) if using the bmw tool. Hold the pulley still with tool 11 5 030 or its equivalent.
  18.  
  19. Install the transmission and the radiator with oiler cooler. Tighten the oil cooler lines to 22-29 ft. lbs. (30-40 Nm).
  20.  
  21. Install the hood and the washer jets. Fill and check the engine fluids. Bleed the cooling system and check for leaks.
  22.  

 
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