BMW Cars 1999-06

Engine 2

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Removal & Installation



E36 Models

NOTE
Engine removal on the E36 models requires the transmission and intake manifold to be removed prior to removing the engine.

  1. Properly relieve the fuel system pressure. Refer to Section 5 for specific details.
  2.  
  3. Allow the engine coolant temperature to cool below 100°F (38°C).
  4.  
  5. Note the radio code and disconnect the negative battery cable.
  6.  
  7. Remove the hood or place the hood in the service position as outlined in Section 10.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. If equipped, remove the lower engine cover.
  12.  
  13. Place a suitable drain pan under the vehicle and drain the radiator, then remove the engine block coolant drain located just beneath the exhaust manifold. On 4-cylinder models the drain plug is toward the rear of the block. On 6-cylinder engines, if the block is cast iron the plug is near the exhaust ports for cylinders four and five, on aluminum engines the plug is near cylinders two and three. Once drained, reinstall the drain plug using a new sealing washer.
  14.  
  15. On vehicles equipped with automatic transmissions, place a suitable drain pan under the transmission cooling lines at the radiator, disconnect and drain the cooling lines. DO NOT drain the transmission fluid into the same container as the coolant. Keep all fluids separated for proper recycling.
  16.  
  17. Carefully lower the vehicle then remove the engine cooling fan, then the radiator. For specific details refer to the removal procedures outlined in this section.
  18.  
  19. On 4-cylinder models, label and disconnect the wiring harness electrical connector for the ignition coil pack. On M44 engines, remove the coil pack from the mounting bracket and secure the coil pack to the top of the engine.
  20.  
  21. On 6-cylinder models, remove the valve cover trim panel, then label and disconnect the ignition coil connectors and place the wiring harness aside.
  22.  
  23. Remove the following. For specific details refer to the intake manifold removal procedures in this section:

    Air filter housing
     
    Fresh air intake duct for the climate control at the upper firewall
     
    Throttle cable, and if equipped, cruise control cable
     
    Engine oil dipstick guide tube (plug hole in oil pan when removed)
     
    Intake manifold (6-cylinder engines)
     
    Upper intake manifold (4-cylinder engines)
     
    Left side engine wiring harness
     
    Lower intake manifold (4-cylinder engines)
     

  24.  
  25. Cover the exposed cylinder head intake ports with shop towels or duct tape to prevent debris from entering the engine.
  26.  
  27. Place a suitable drain pan under the heater hoses, loosen heater hose clamps and remove the hoses, draining the residual coolant into a suitable container.
  28.  
  29. Remove the accessory drive belt, and if equipped, remove the air conditioner belt.
  30.  
  31. Remove the power steering reservoir leaving the hoses attached and place aside.
  32.  
  33. Remove the power steering pump mounting bolts and remove the pump with the hoses attached and place aside. Make sure to properly support the pump.
  34.  
  35. If equipped, remove the air conditioner compressor mounting bolts and remove the compressor with the high pressure hoses attached and place aside. Make sure to properly support the compressor.
  36.  
  37. Remove the starter motor as outlined in Section 2.
  38.  


NOTE
On some models the starter motor has a dowel pin between the two mounting bolts that may corrode in place. Move the starter side-to-side to help release the dowel pin.

  1. Attach Tool No. 00 0 200 engine support carriage and Tool No. 11 0 030 lifting hook or their equivalents to support the rear of the engine with the lifting eye just above the starter motor area once the transmission is removed.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. On 4-cylinder models, if not previously removed, disconnect and remove the fuel lines on the lower left side of the engine.
  6.  
  7. Remove the exhaust system.
  8.  
  9. Remove the exhaust heat shields as necessary to access the driveshaft.
  10.  
  11. Remove the transmission as outlined in Section 7.
  12.  
  13. Carefully lower the vehicle.
  14.  
  15. Attach a suitable engine lifting sling to the front and rear lift hooks on the intake side of the engine.
  16.  
  17. Disconnect the engine ground cable at the right front engine mount.
  18.  
  19. Remove the left and right engine mount fasteners.
  20.  
  21. Inspect the engine to make sure all hoses, cables and electrical connectors have been properly disconnected.
  22.  
  23. Using a suitable engine lifting device, carefully lift the engine up and out of the vehicle.
  24.  



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Fig. The fresh air intake hose is located under the upper radiator trim cover-M44 engine shown



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Fig. Remove the four fasteners, then lift the cover off-M44 engine shown



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Fig. The fresh air intake duct is secured to the front body panel with a locking clip. Simply lift the clip upward to release-M44 engine shown



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Fig. With the trim cover removed and locking tab released, the intake hose is lifted up and unsnapped from the air filter housing-M44 engine shown



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Fig. Remove the two fasteners at the top of the cooling fan shroud, then . . .



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Fig. . . . lift the cooling fan slightly to access and disconnect the electrical connector and . . .



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Fig. . . . carefully lift the fan assembly upward from the radiator-M44 engine shown



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Fig. Cooling fan removal tools. Note the spindle has left hand threads and the fan is removed by turning it clockwise



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Fig. The ignition leads on the coil are released by lifting the locking bracket-E36 6-cylinder models



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Fig. Power steering pump mounting bolts-E36 6-cylinder models



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Fig. Throttle cable-E36 6-cylinder models



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Fig. Front and rear intake manifold supports-E36 6-cylinder models



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Fig. Temperature sensor (1), temperature gauge (2), oil pressure switch (3) and idle speed control valve (4) electrical connector locations-E36 6-cylinder models



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Fig. Right engine mount, showing the ground cable attachment-E36 6-cylinder model shown



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Fig. Left engine mount-E36 6-cylinder model shown



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Fig. Air cleaner and air mass sensor-E36 6-cylinder model shown

To install:

  1. Installation is in reverse order of assembly noting the following.
  2.  
  3. When installing the transmission to the engine, insert the locating dowels into the engine to ease assembly.
  4.  
  5. Coat all injector and sealing o-rings with a light film of oil before assembling.
  6.  


NOTE
On models with a water pump mounted cooling fan, the water pump spindle threads for the cooling fan clutch assembly have left hand threads, thus the fan clutch assembly must be rotated counterclockwise to install. As there is a minimum amount of clearance between the water pump and the radiator assembly, rotating the fan clutch assembly to install it onto the water pump spindle may be difficult. To assist with the installation of the fan clutch assembly, use a piece of thin, sturdy string about 3 feet (1 meter) long. Wind the string around the fan clutch mounting nut in a clockwise direction 15-20 revolutions. Position the fan clutch assembly on the water pump spindle squarely and while holding the fan, slowly pull the string to spin the fan clutch mounting nut in a counterclockwise direction. Once the nut begins to thread onto the water pump spindle, remove the remainder of the string.

  1. On 4-cylinder engines, replace the following:

    Intake manifold-to-cylinder head gasket
     
    Upper-to-lower intake manifold gaskets
     
    Inspect the fuel feed o-ring for the fuel rail and replace as necessary
     
    Fuel line hose clamps
     

  2.  
  3. On 6-cylinder engines inspect the manifold seals and replace as necessary.
  4.  
  5. On all models, inspect the oil dipstick tube o-ring and replace as necessary.
  6.  
  7. On vehicles with automatic transmissions:
    1. Connect the automatic transmission cooling lines using new seals on the lines and tighten to 13-15 ft. lbs. (18-21 Nm).
    2.  
    3. Check the transmission fluid level, top off as necessary, and recheck fluid level once the engine has been started.
    4.  

  8.  
  9. Torque the mounting fasteners as follows:
    1. Transmission-to-engine fasteners:

      M8 hex screws: 18 ft. lbs. (25 Nm)
       
      M10 hex screws: 36 ft. lbs. (49 Nm)
       
      M12 hex screws: 54 ft. lbs. (74 Nm)
       
      M8 Torx® bolts: 16 ft. lbs. (22 Nm)
       
      M10 Torx® bolts: 32 ft. lbs. (43 Nm)
       
      M12 Torx® bolts: 53 ft. lbs. (72 Nm)
       

    2.  
    3. Engine mount fasteners:

      M8: 16 ft. lbs. (22 Nm)
       
      M10: 35 ft. lbs. (47 Nm)
       

    4.  
    5. Intake manifold to cylinder head fasteners:

      M6: 72 inch lbs. (8 Nm)
       
      M7: 11 ft. lbs. (15 Nm)
       
      M8 16 ft. lbs. (22 Nm)
       

    6.  
    7. Fan clutch (left hand thread) to water pump spindle: 30 ft. lbs. (40 Nm)
    8.  

  10.  
  11. Refill and bleed the cooling system as necessary.
  12.  


NOTE
It may be necessary to bleed the cooling system a second time once the engine has been started.

  1. Check and top off all fluid levels.
  2.  
  3. Install the engine splash shield.
  4.  
  5. Connect the negative battery cable and re-code the radio.
  6.  
  7. Re-check all fluids after the engine has been started, and top off as necessary.
  8.  

M44 1.9L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Battery ground cable
     
    Engine splash guards
     
    Transmission
     
    Hood gas spring and prop rod, then support the hood safely in the fully open position
     
    Engine cooling fan cowling
     
    Fan clutch mounting nut from the shaft. The shaft uses left-hand threads; thus the nut is turned clockwise to remove.
     
    Coolant
     
    Lower radiator expansion tank hose, the engine coolant hoses and the heater hoses from the firewall
     
    Air flow meter electrical terminal, and then lift the air sensor with the air cleaner housing up and out of the engine compartment
     
    Unclip the throttle cable and release the cable with the rubber holder
     
    Relieve the residual fuel line pressure
     
    Fuel rail feed and return lines, then pull off the vent hose to the canister for tank venting
     
    Vacuum fitting at the brake booster
     
    Ignition coil electrical terminals, then remove the wire connections at the alternator and starter
     
    Wire connections from the throttle valve potentiometer, then remove the tank venting valve plug located next to the air cleaner
     
    Fuel injector connector located near to the fuel pipes, then disconnect the idle speed control connector at the rear of the intake manifold and the oil pressure switch electrical connection
     
    Front and rear intake manifold supports
     
    Coolant temperature senders for the gauge and the Digital Motor Electronics (DME)
     
    Remaining electrical wiring harnesses
     

  4.  
  5. Support the weight of the engine and remove the engine mounting bolts and the engine ground strap.
  6.  
  7. Lift the engine and remove the engine from the vehicle.
  8.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    6mm fasteners: 61 inch lbs. (7 Nm)
     
    7mm fasteners: 10 ft. lbs. (13 Nm)
     
    8mm fasteners: 16 ft. lbs. (22 Nm)
     
    10mm fasteners: 31 ft. lbs. (42 Nm)
     

  2.  

M44 Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Battery ground cable
     
    Engine splash guards
     
    Transmission
     
    Hood gas spring and prop rod, then support the hood safely in the fully open position
     
    Engine cooling fan cowling
     
    Fan clutch mounting nut from the shaft. The shaft uses left-hand threads; thus the nut is turned clockwise to remove.
     
    Coolant
     
    Lower radiator expansion tank hose, the engine coolant hoses and the heater hoses from the firewall
     
    Air flow meter electrical terminal, and then lift the air sensor with the air cleaner housing up and out of the engine compartment
     
    Unclip the throttle cable and release the cable with the rubber holder
     
    Relieve the residual fuel line pressure
     
    Fuel rail feed and return lines, then pull off the vent hose to the canister for tank venting
     
    Vacuum fitting at the brake booster
     
    Ignition coil electrical terminals, then remove the wire connections at the alternator and starter
     
    Wire connections from the throttle valve potentiometer, then remove the tank venting valve plug located next to the air cleaner
     
    Fuel injector connector located near to the fuel pipes, then disconnect the idle speed control connector at the rear of the intake manifold and the oil pressure switch electrical connection
     
    Front and rear intake manifold supports
     
    Coolant temperature senders for the gauge and the Digital Motor Electronics (DME)
     
    Remaining electrical wiring harnesses
     

  4.  
  5. Support the weight of the engine and remove the engine mounting bolts and the engine ground strap.
  6.  
  7. Lift the engine and remove the engine from the vehicle.
  8.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    6mm fasteners: 61 inch lbs. (7 Nm)
     
    7mm fasteners: 10 ft. lbs. (13 Nm)
     
    8mm fasteners: 16 ft. lbs. (22 Nm)
     
    10mm fasteners: 31 ft. lbs. (42 Nm)
     

  2.  

M50/M52/S50 Engines
  1. Disconnect the battery terminals, negative side first and remove the battery. 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. Install the remaining components in the reverse order of removal.
  6.  
  7. Install the fan using tool 11 5 040 or equivalent. Torque the nut to 29 ft. lbs. (40 Nm). If using the fan 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.
  8.  
  9. 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.
  10.  

M52 2.5L, M52 2.8L, And S52 3.2L Engines


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Fig. Cooling fan removal tools



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Fig. Ignition leads on coil-3 Series with M52/S52 engines



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Fig. Power steering pump mounting bolts-3 Series with M52/S52 engines



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Fig. Throttle cable-3 Series with M52/S52 engines



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Fig. Front and rear intake manifold supports-3 Series with M52/S52 engines



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Fig. Temperature sensor (1), temperature gauge (2), oil pressure switch (3) and idle speed control valve (4) electrical connector locations-3 Series with M52/S52 engines



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Fig. Right engine mount, showing the ground cable attachment-3 Series with M52/S52 engines



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Fig. Left engine mount-3 Series with M52/S52 engines



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Fig. Air cleaner and air mass sensor-3 Series with M52/S52 engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery terminal
     
    Engine splash guard
     
    Transmission assembly
     

  8.  
  9. Press the hood hinge so it goes over center and support hood safely in the fully open position.
  10.  
  11. Remove or disconnect the following:

    Air mass sensor connector and loosen the air intake duct hose clamp, then remove the air cleaner housing assembly
     
    Hoses for the idle speed control valve and the crankcase breather
     
    Air ducting for the alternator. Pull out the fan cowl expansion rivets and remove the cowl upwards.
     
    Fan and fan clutch assembly, keeping it upright
     
    Upper and lower radiator hoses
     
    Coolant level switch and plug the cooler lines for the automatic transmission
     
    Right side coolant hose and the temperature sensor
     
    Radiator
     
    Heater coolant hoses from the heater and heater valve
     
    Grill from the air intake cowl at the base of the windshield
     

  12.  
  13. To remove the cowl:
    1. Remove the electrical lead tray.
    2.  
    3. Remove the fasteners on the right side cowl holder bracket and the screw on the left side.
    4.  
    5. Remove the cowl from the engine compartment.
    6.  

  14.  
  15. Remove or disconnect the following:

    Throttle cable cover. Unclip the throttle cable and pull the cable out along with the rubber holder.
     
    Vacuum fitting from the brake booster and plug the openings
     
    Engine and intake manifold covers. Remove the bolt holding the ground strap on the front engine lifting bracket. Reinstall the bolt before lifting the engine.
     
    Bolts holding the ignition coil wire harness plug plate and remove the plug plate
     
    Ignition coil electrical plugs. Remove the plug plate complete with the electrical leads.
     
    Cylinder head vent hose and the intake air temperature sensor connector
     
    Fuel tank vent hose and the throttle body coolant hoses from the throttle body
     
    Throttle valve switch electrical connector
     
    Connector from the idle speed control valve mounted on the manifold
     
    Fuel rail feed and return hoses
     
    Intake manifold support brackets and the intake manifold fasteners mounting the manifold to the intake ports
     
    Intake manifold
     
    Electrical connectors from the fuel injection temperature sensor, temperature gauge, the oil pressure switch and the idle speed control valve
     
    Cylinder identifying sender plug (black) and the pulse sender plug (gray) for the Digital Motor Electronics (DME)
     
    O 2 S sensor
     
    Electric leads from the alternator and the starter. Remove the electrical connector to separate the engine wiring harness from the fuse panel tray and place the engine wiring harness to the side.
     
    Drive belt for the power steering pump and the air conditioner compressor
     
    Power steering pump and place to the side without disconnecting the hoses
     
    Air conditioner compressor and place to the side without disconnecting the lines
     

  16.  
  17. Carefully support the engine and remove the engine mounts and ground strap.
  18.  
  19. Slowly and carefully lift the engine out of the vehicle being careful of the painted surfaces for the front radiator mount.
  20.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    6mm fasteners: 61 inch lbs. (7 Nm)
     
    7mm fasteners: 10 ft. lbs. (13 Nm)
     
    8mm fasteners: 16 ft. lbs. (22 Nm)
     
    10mm fasteners: 31 ft. lbs. (42 Nm)
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable, battery, and battery tray
     
    Transmission assembly
     
    Alternator air cooling duct
     
    Plug to the intake air flow meter and air cleaner housing assembly
     
    Fan cowl
     
    Fan pulley
     
    Coolant hoses from the radiator and coolant level switch plug
     
    With automatic transmission, oil lines to the radiator and plug the lines
     
    Lower radiator hose and trim panel from the right side of the engine compartment
     
    Electrical connector for the air conditioner temperature switch
     
    Radiator
     
    Heater hoses from the heater valve and the heater core
     
    Throttle cable cover and throttle cable cover
     
    Vacuum fitting from the brake booster and plug the openings
     
    Engine and intake manifold covers. Remove the bolt holding the ground strap on the front engine lifting bracket. Reinstall the bolt before lifting the engine.
     
    Bolts holding the plug plate for the ignition coil wiring harness and remove the plug plate
     
    Ignition coil electrical connectors. Remove the plug plate complete with the electrical terminals.
     
    Cylinder head vent hose and air temperature sensor plug
     
    Tank venting hose and the throttle body coolant hoses from the throttle body
     
    Throttle valve switch plug. Unclip the idle speed control valve mounted on the manifold.
     
    Fuel feed and return hoses from the fuel rail
     
    Intake manifold
     
    Electrical connectors from the temperature sensor, temperature gauge, the oil pressure switch and the idle speed control valve. Disconnect the cylinder identifying sender connector (black) and the pulse sender connector (gray) for the Digital Motor Electronics (DME), then disconnect the Oxygen (O 2 S) sensor connector from the holder.
     
    Electric wire harness from the alternator and the starter. Remove the connector for the main engine wiring harness and place the engine wiring harness to the side.
     
    Drive belt for the power steering pump and the air conditioner compressor
     
    Power steering pump and place to the side without disconnecting the hoses
     
    Air conditioner compressor and place to the side without disconnecting the high pressure lines
     
    Engine mounts and ground strap. Slowly lift the engine out of the vehicle using care to not damage the painted surfaces of the front radiator mount.
     

  8.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    6mm fasteners: 61 inch lbs. (7 Nm)
     
    7mm fasteners: 10 ft. lbs. (13 Nm)
     
    8mm fasteners: 16 ft. lbs. (22 Nm)
     
    10mm fasteners: 31 ft. lbs. (42 Nm)
     

  2.  

M54 And S54 Engines


Click image to see an enlarged view

Fig. Cooling fan removal tools



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Fig. Engine mount, showing the ground cable attachment



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Fig. Engine front and rear lift points

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Raise the hood all the way up into the service position. This usually requires disconnecting the gas struts and securing the hood hinges with bolts.
  8.  
  9. Remove or disconnect the following:

    Negative battery terminal
     
    Cables from the duct on the filter housing
     
    Filter housing
     
    Engine splash guard
     
    Transmission assembly
     
    A/C compressor drive belt
     
    A/C compressor and secure aside
     
    Upper and lower radiator hoses
     
    Radiator
     
    Cover from fuel injectors
     
    Both Oxygen (O 2 s sensor monitors
     
    Intake manifold
     
    Hoses from water pipe and heating valve
     
    Engine wiring harness and secure aside
     
    Power steering reservoir and secure aside
     
    Fan and fan clutch assembly
     
    Power steering pump and secure aside
     

  10.  
  11. Carefully support the engine and remove the engine mounts and ground strap.
  12.  
  13. Slowly and carefully lift the engine out of the vehicle being careful of the painted surfaces for the front radiator mount.
  14.  
  15. Installation is the reverse of the removal procedure, while using the following torque values:

    6mm fasteners: 61 inch lbs. (7 Nm)
     
    7mm fasteners: 10 ft. lbs. (13 Nm)
     
    8mm fasteners: 16 ft. lbs. (22 Nm)
     
    10mm fasteners: 31 ft. lbs. (42 Nm)
     

  16.  

M60/M62 Engines
  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. The remaining components are installed in the reverse order of removal.
  8.  
  9. Install the transmission and the radiator. Fill the cooling system and check the engine fluids. Install the splash shield and connect the battery.
  10.  
  11. Run the engine and check for leaks. Bleed the cooling system.
  12.  

M62 4.4L And M73 5.4 L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Splash guard
     
    Transmission assembly
     
    Power steering pump with the hoses attached
     
    Air conditioner compressor, leaving the high pressure hoses attached
     
    Air intake hose, then the mounting nut, and air cleaner housing assembly
     
    On 750 models, oil filter cover bolt, oil cooler lines and the connector from the oil pressure switch
     
    Idle speed control valve and intake hoses. Disconnect the electrical connector, remove the mounting nut, and pull the idle speed control valve out of the air intake hose.
     
    Air flow sensor, disconnecting the vacuum hose from the PCV system at the same time
     
    Coolant reservoir expansion tank
     
    Engine coolant hoses at both the control valve and at the heater core
     
    Throttle and cruise control cables at the throttle lever, then remove the cable housing retainer and remove the housing and cables
     
    Light gauge wires from the starter motor, and with the positive battery cable disconnected from the battery, remove the starter motor with the battery cable attached
     
    Fresh air hose from the alternator
     
    Electrical connection for the O 2 S sensor, and disconnect the surrounding electrical connections and place the wire harness safely aside
     
    Fuel rail supply and return lines
     
    Fuel pipe at the injector supply manifold, then disconnect the harness electrical connectors. Disconnect the electrical connector at the throttle body, lift off the protective caps, remove the attaching nuts for the protective cover for the fuel injector wiring harness and remove it.
     
    Engine ground cable, then remove the engine mount nut from the top on both sides
     

  8.  
  9. Attach a suitable lifting attachment to the engine and carefully support the engine.
  10.  
  11. Slowly and carefully lift the engine out of the vehicle, tilting the front of the engine upward for clearance. Use care to not damage the painted surfaces of the front radiator support.
  12.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    6mm fasteners: 61 inch lbs. (7 Nm)
     
    7mm fasteners: 10 ft. lbs. (13 Nm)
     
    8mm fasteners: 16 ft. lbs. (22 Nm)
     
    10mm fasteners: 31 ft. lbs. (42 Nm)
     

  2.  

M62 4.4L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine splash shield
     
    Radiator
     
    If equipped, nut holding the transmission oil cooler lines to the engine oil pan
     
    Transmission assembly
     
    Drive belts for the power steering pump and the air conditioner compressor, then remove the bolts holding the pump and compressor to the engine and remove them from the engine, keeping the high pressure hoses connected. Secure the pump and compressor out of the way and without any tension or binding on the hoses.
     
    Hoses from the coolant reservoir expansion tank, then remove the fasteners on the side of the expansion tank and remove the expansion tank from the engine compartment
     
    Heater hoses from the heater control valve and the heater core inlet pipe
     
    Electrical connections to the ignition coil, then the air cleaner housing assembly
     
    Idle speed control valve from the intake duct
     
    Wire harness connectors for the air flow meter, then the ducting to the air flow meter and crankcase breather vacuum line
     
    With a cable operated throttle, cruise control cable and the throttle cable at the throttle, then remove the cable mounting bracket
     
    With an electronically controlled throttle, electrical connector to the throttle control unit
     
    Wiring harness from the starter, then the electrical connectors located near the starter motor assembly
     
    Oil level sender connector and the wiring harness from the alternator
     
    Air duct to the alternator
     
    Fuel tank venting valve and the hose to the canister
     
    Fuels lines for the fuel rail
     
    Vacuum line from the brake booster and plug the opening
     
    Wiring harness connections to the temperature sensors and the Digital Motor Electronics (DME)
     
    Engine ground cable and verify that all remaining fluid lines or electrical leads have been disconnected and properly placed aside
     
    Engine mount nuts and bolts and carefully lift the engine from the vehicle
     

  8.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    6mm fasteners: 61 inch lbs. (7 Nm)
     
    7mm fasteners: 10 ft. lbs. (13 Nm)
     
    8mm fasteners: 16 ft. lbs. (22 Nm)
     
    10mm fasteners: 31 ft. lbs. (42 Nm)
     

  2.  

 
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