BMW Cars 1999-06

Removal & Installation

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E30 Models



S14 Engine
  1. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Remove the fan. The fan must be held stationary on tool 11 5 030 or some sort of flat-bladed tool cut to fit over the hub and drilled to fit over 2 of the studs on the front of the pulley. Remove the fan coupling nut; left hand thread-turn clockwise to remove.
  4.  
  5. Remove the belt and pulley.
  6.  
  7. Disconnect the hoses from the water pump. Remove the 7 mounting bolts and remove the water pump.
  8.  

To install:

  1. Clean the gasket surfaces and use a new gasket.
  2.  
  3. Install the water pump in position. Torque M8 bolts to 16-17 ft. lbs. (20-24 Nm) and M6 bolts to 6-7 ft. lbs. (8-10 Nm).
  4.  
  5. Connect the hoses.
  6.  
  7. Install the pulley and tighten the bolts to 6-7 ft. lbs. (8-10 Nm). Install the belt and tighten. Install the fan.
  8.  
  9. Add coolant and bleed the cooling system. Connect the negative battery terminal.
  10.  

E36 Models



  1. Note the radio security code and disconnect the negative battery cable.
  2.  
  3. Place a suitable drain pan under the vehicle.
  4.  
  5. Remove the radiator drain plug and drain the coolant into a sealable container.
  6.  
  7. Remove the engine block drain plug located just below the exhaust manifold and drain the coolant into a sealable container.
  8.  
  9. Remove the engine cooling fan and shroud as outlined in this section.
  10.  
  11. Loosen but do not fully remove the water pump pulley bolts.
  12.  
  13. Label the direction of the drive belt(s), then remove the belt(s). Inspect and replace as necessary.
  14.  
  15. Remove the water pump pulley bolts, then remove the pulley.
  16.  
  17. Carefully remove all of the water pump mounting bolts using a crisscross pattern. As the bolts may have corroded in place, spray them with a light coating of a penetrating lubricant and use 6 point wrenches or sockets during removal.
  18.  
  19. Apply an anti-seizing compound to two 6 x 1.0 x40mm bolts and thread them into the top and bottom threaded holes in the water pump housing. Thread the bolts lightly until they are seated. Then, alternately turn each bolt one turn at a time to extract the water pump. Watch the water pump as it is being removed. It should come straight out of the engine block. If the pump cocks to one side, loosen that removal bolt and tap the pump inward until its mating surface is parallel with the block.
  20.  



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Fig. Loosen the water pump pulley bolts before removing the drive belt-M44 engine shown



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Fig. Once the pulley is removed, carefully loosen the mounting bolts in a crisscross pattern



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Fig. Thread two 6 x 1.0 x 40mm bolts into the top and bottom threaded holes in the pump housing



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Fig. As the bolts are tightened, the water pump is extracted from the engine block. Note, do to availability, we used bolts of a different length



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Fig. Once the O-ring clears the engine block, the water pump is easily removed



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Fig. Coat the water pump O-ring with an anti-seizing compound before installing . . .



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Fig. . . . also coat the water pump-to-engine block fasteners with an anti-seizing compound before installing

To install:

  1. Inspect the following items and replace as necessary:

    Hose clamps
     
    Radiator Cap
     
    Coolant hoses
     
    Coolant thermostat
     
    Accessory drive belts
     
    Accessory drive belt tensioning and guide rollers
     

  2.  
  3. Install a new O-ring on the water pump, and coat the O-ring with an anti-seizing compound.
  4.  
  5. Slide the water pump into the engine block until it is seated.
  6.  
  7. Coat the threads of the water pump-to-engine block mounting fasteners with an anti-seizing compound.
  8.  
  9. Tighten and torque the fasteners in two steps using a crisscross pattern, as follows:

    M6: 88.5 inch lbs. (10 Nm)
     
    M7: 11 ft. lbs. (15 Nm)
     
    M8: 15 ft. lbs. (20 Nm)
     

  10.  
  11. The balance of installation is in reverse order of removal noting the following.
  12.  
  13. Fill the cooling system using a 50 / 50 mixture of an approved coolant and if available distilled water. DO NOT exceed a mixture of greater than 60 % coolant to water.
  14.  
  15. Bleed the cooling system as necessary.
  16.  


NOTE
Squeezing and releasing the lower radiator hose will help to force out trapped air pockets.

  1. Upon completion, check for fluid leaks and normal operation.
  2.  
  3. After the engine has reached operating temperature, allow to cool, recheck the coolant level and top off as necessary.
  4.  

M20 Engine





Click image to see an enlarged view

Fig. Compress the timing belt tensioner spring and clamp with tool 11 5 010 or equivalent

  1. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Remove the distributor cap and rotor. Remove the rotor adapter, the dust shield and the distributor housing.
  4.  
  5. Remove the fan. The fan must be held stationary on tool 11 5 030 or some sort of flat-blade tool cut to fit over the hub and drilled to fit over 2 of the studs on the front of the pulley. Remove the fan coupling nut; left hand thread-turn clockwise to remove.
  6.  
  7. Remove the belt and pulley.
  8.  
  9. Remove the rubber guard and distributor and or upper timing belt cover.
  10.  
  11. Compress the timing tensioner spring and clamp pin with the proper tool.
  12.  


NOTE
Observe the installed position of the tensioner spring pin on the water pump housing for reinstallation purposes.

  1. Remove the water hoses, remove the 3 water pump bolts and remove the pump.
  2.  

To install:

  1. Clean the gasket surfaces and use a new gasket.
  2.  
  3. Install the water pump in position. Note the position of the tensioner spring pin. Torque M8 bolts to 16-17 ft. lbs. (20-24 Nm) and M6 bolts to 53-62 inch lbs. (8-10 Nm). Connect the hoses.
  4.  
  5. Release the tensioner from the holding pin. Install the upper timing cover. Install the pulley and tighten the bolts to 6-7 ft. lbs. (8-10 Nm). Install the belt and tighten.
  6.  
  7. Install the fan, distributor housing and dust shield. Tighten the rotor adapter to 39-47 ft. lbs. (55-65 Nm). Install the rotor, O-ring and cap.
  8.  
  9. Add coolant and bleed the cooling system. Connect the negative battery terminal.
  10.  

M42 Engine



  1. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Remove the fan. Remove the drive belt and the water pump pulley.
  4.  
  5. Remove the pump mounting bolts.
  6.  
  7. Screw 2 bolts into the tapped bores and press the water pump out of the cover uniformly.
  8.  

To install:

  1. Lubricate and install a new O-ring.
  2.  
  3. Install the water pump and tighten the bolts to 80 inch lbs. (9 Nm).
  4.  
  5. Install the pulley and tighten the bolts to 80 inch lbs. (9 Nm). Install the belt and fan.
  6.  
  7. Fill and bleed the cooling system. Connect the negative battery terminal.
  8.  

M44 1.9L, M52 2.5L, M52 2.8L, And S52 3.2L Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The water pump can be separated from the engine by using 2 M6 bolts threaded into the tapped bores of the water pump housing. To press the water pump away from the engine thread the bolts evenly.



    Negative battery cable
     
    With an upper fan cowl, fan cowl
     
    Air cleaner housing complete with the air flow sensor, if necessary
     
    On M62B44 4.4L and M73B54 5.4L engines, coolant hoses from the upper water pump housing
     
    Fan clutch mounting nut from the water pump shaft. The shaft uses left-hand threads; thus the nut is turned clockwise to remove.
     
    Accessory drive belt
     
    Fasteners securing the pulley to the water pump
     
    Water pump mounting bolts
     
    Water pump assembly
     

  6.  

To install:

  1. Clean and remove any residual debris or gasket material from the engine mounting surface for the water pump.
  2.  
  3. Lubricate and install a new O-ring.
  4.  
  5. Install the water pump and tighten the bolts as follows:

    M6 bolts: 78 inch lbs. (9 Nm)
     
    M8 bolts:16 ft. lbs. (22 Nm)
     

  6.  
  7. Install or disconnect the following:
    NOTE
    The water pump spindle threads for the cooling fan and fan clutch assembly are left hand threads hence 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.



    Water pump pulley onto the water pump
     
    Cooling fan and fan clutch assembly onto the threaded water pump spindle
     



    Fan clutch assembly using tool No. 11-5-040. Nut: 29 ft. lbs. (40 Nm). If using the fan tool, torque the nut to 22 ft. lbs. (30 Nm); as the additional length of the tool multiplies the torque to achieve 29 ft. lbs. (40 Nm) at the nut.
     

  8.  
  9. The remaining components are installed in the reverse order from which they were removed.
  10.  
  11. Fill the cooling system.
  12.  
  13. Start the engine and check for leaks.
    NOTE
    It may be necessary to bleed the cooling system a second time once the engine has been started.

  14.  

M44 Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The water pump can be separated from the engine by using 2 M6 bolts threaded into the tapped bores of the water pump housing. To press the water pump away from the engine thread the bolts evenly.



    Negative battery cable
     
    With an upper fan cowl, fan cowl
     
    Air cleaner housing complete with the air flow sensor, if necessary
     
    On M62B44 4.4L and M73B54 5.4L engines, coolant hoses from the upper water pump housing
     
    Fan clutch mounting nut from the water pump shaft. The shaft uses left-hand threads; thus the nut is turned clockwise to remove.
     
    Accessory drive belt
     
    Fasteners securing the pulley to the water pump
     
    Water pump mounting bolts
     
    Water pump assembly
     

  6.  

To install:

  1. Clean and remove any residual debris or gasket material from the engine mounting surface for the water pump.
  2.  
  3. Lubricate and install a new O-ring.
  4.  
  5. Install the water pump and tighten the bolts as follows:

    M6 bolts: 78 inch lbs. (9 Nm)
     
    M8 bolts:16 ft. lbs. (22 Nm)
     

  6.  
  7. Install or disconnect the following:
    NOTE
    The water pump spindle threads for the cooling fan and fan clutch assembly are left hand threads hence 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.



    Water pump pulley onto the water pump
     
    Cooling fan and fan clutch assembly onto the threaded water pump spindle
     



    Fan clutch assembly using tool No. 11-5-040. Nut: 29 ft. lbs. (40 Nm). If using the fan tool, torque the nut to 22 ft. lbs. (30 Nm); as the additional length of the tool multiplies the torque to achieve 29 ft. lbs. (40 Nm) at the nut.
     

  8.  
  9. The remaining components are installed in the reverse order from which they were removed.
  10.  
  11. Fill the cooling system.
  12.  
  13. Start the engine and check for leaks.
    NOTE
    It may be necessary to bleed the cooling system a second time once the engine has been started.

  14.  

M50/M52/S50 Engines



  1. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Remove the fan cowl and fan, if necessary.
  4.  
  5. Remove the drive belt and the pulley. Disconnect the bracket, if necessary.
  6.  
  7. Remove the air cleaner with the air flow sensor, if needed.
  8.  
  9. Disconnect the cooling hoses and remove the water pump.
  10.  
  11. The installation is the reverse of the removal procedure. Torque the M8 bolts to 16 ft. lbs. (22 Nm) and the M6 bolts to 6.5 ft. lbs. (9 Nm).
  12.  

M54 And S54 Engines





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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.  

M54 Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    With an upper fan cowl, fan cowl
     
    Air cleaner housing complete with the air flow sensor, if necessary
     
    Fan clutch mounting nut from the water pump shaft. The shaft uses left-hand threads; thus the nut is turned clockwise to remove.
     
    Accessory drive belt
     
    Fasteners securing the pulley to the water pump
     
    Water pump mounting bolts
     
    Water pump assembly
     

  6.  


NOTE
The water pump can be separated from the engine by using 2 M6 bolts threaded into the tapped bores of the water pump housing. To press the water pump away from the engine thread the bolts evenly.

To install:

  1. Clean and remove any residual debris or gasket material from the engine mounting surface for the water pump.
  2.  
  3. Lubricate and install a new O-ring.
  4.  
  5. Install the water pump and tighten the bolts as follows:

    M6 bolts: 78 inch lbs. (9 Nm)
     
    M8 bolts: 16 ft. lbs. (22 Nm)
     

  6.  
  7. Install or disconnect the following:

    Water pump pulley onto the water pump
     
    Cooling fan and fan clutch assembly onto the threaded water pump spindle
     

  8.  


NOTE
The water pump spindle threads for the cooling fan and fan clutch assembly are left hand threads hence 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.



fan clutch assembly using tool No. 11-5-040. Nut: 29 ft. lbs. (40 Nm). If using the fan tool, torque the nut to 22 ft. lbs. (30 Nm); as the additional length of the tool multiples the torque to achieve 29 ft. lbs. (40 Nm) at the nut.
 
The remaining components are installed in the reverse order from which they were removed
 

  1. Fill the cooling system.
  2.  
  3. Start the engine and check for leaks.
  4.  


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

M60/M62 Engines



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the heat shields at the left and right hand sides of the front axle carrier.
  6.  
  7. Remove the front and rear engine splash guards.
  8.  
  9. Remove the fan. The fan must be held stationary with tool 11-5-030 or some sort of flat blade cut to fit over the hub and drilled to fit over 2 of the studs on the front of the pulley. Remove the fan coupling nut; left hand thread-turn clockwise to remove.
  10.  
  11. Remove the drive belt tensioner, and the serpentine drive belt.
  12.  
  13. Remove the vibration damper and hub. There are eight mounting bolts, and a central bolt. Use a suitable holding tool 11-2-230 or equivalent for the central bolt.
  14.  
  15. Disconnect the coolant hose at the cover of the thermostat housing. Remove the thermostat.
  16.  
  17. Remove the water pump pulley by counter holding the pulley with the drive belt and removing the four pulley mounting bolts.
  18.  
  19. Disconnect the hoses from the water pump. Remove the 6 mounting bolts and remove the water pump.
  20.  

To install:

  1. Clean the gasket surfaces and use a new gasket.
  2.  
  3. Check for the correct seating of the dowel sleeves. Install the water pump in position. Torque the M8 mounting bolts to 16 ft. lbs. (22 Nm), and the M6 mounting bolts to 7 ft. lbs. (10 Nm). Connect the hoses.
  4.  
  5. Install the vibration damper and hub. Torque the eight mounting bolts to 17 ft. lbs. (24 Nm). Torque the central mounting bolt in four steps as follows:

    An initial torque of 74-81 ft. lbs. (100-110 Nm)
     
    Add an additional 60 degrees torque
     
    Add an additional 60 degrees torque
     
    Then add an additional 30 degrees torque.
     

  6.  
  7. Install the thermostat. Connect the coolant hose.
  8.  
  9. Install the drive belt tensioner and the drive belt.
  10.  
  11. Install the pulley and tighten the bolts to 6-7 ft. lbs. (8-10 Nm). Install the belt and tighten. Install the fan.
  12.  
  13. Install the heat shields and splash guards.
  14.  
  15. Connect the negative battery terminal.
  16.  
  17. Refill and bleed the cooling system.
  18.  

M62 4.4L Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    With an upper fan cowl, fan cowl
     
    Air cleaner housing complete with the air flow sensor, if needed
     
    Accessory drive belts
     
    Bolts that secure the crankshaft pulley vibration damper. Do not remove the center bolt.
     
    Coolant hoses from the upper water pump housing
     
    Fan clutch mounting nut from the water pump shaft. The shaft uses left-hand threads; thus the nut is turned clockwise to remove.
     
    Fasteners securing the pulley to the water pump
     
    Thermostat housing from the water pump assembly
     
    Water pump mounting bolts
     
    Water pump assembly
     

  6.  

To install:

  1. Clean and remove any residual debris or gasket material from the engine mounting surface for the water pump.
  2.  
  3. Install or connect the following:

    Water pump with a new gasket. Tighten the M6 bolts to 78 inch lbs. (9 Nm), and the M8 bolts to 16 ft. lbs. (22 Nm).
     
    Thermostat and thermostat housing onto the water pump assembly using a new housing gasket sealing ring
     
    Crankshaft pulley vibration damper using new fasteners. Be sure to align the damper with the dowel.
     
    Water pump pulley onto the water pump
     
    Accessory drive belts
     
    Cooling fan and fan clutch assembly onto the threaded water pump spindle
     

  4.  


NOTE
The water pump spindle threads for the cooling fan and fan clutch assembly are left hand threads hence 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. Install or connect the following:

    Fan clutch assembly using tool No. 11-5-040. Nut: 29 ft. lbs. (40 Nm). If using the fan tool, torque the nut to 22 ft. lbs. (30 Nm); as the additional length of the tool multiplies the torque to achieve 29 ft. lbs. (40 Nm) at the nut.
     
    The remaining components are installed in the reverse order from which they were removed
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  


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

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

    Negative battery cable
     
    With an upper fan cowl, fan cowl
     
    Air cleaner housing complete with the air flow sensor, if needed
     
    Accessory drive belts
     
    8 bolts that secure the crankshaft pulley vibration damper. Do not remove the center bolt.
     
    Coolant hoses from the upper water pump housing
     
    Fan clutch mounting nut from the water pump shaft. The shaft uses left-hand threads; thus the nut is turned clockwise to remove.
     
    Fasteners securing the pulley to the water pump
     
    Thermostat housing from the water pump assembly
     
    Water pump mounting bolts
     
    Water pump assembly
     

  6.  

To install:

  1. Clean and remove any residual debris or gasket material from the engine mounting surface for the water pump.
  2.  
  3. Install or connect the following:
    NOTE
    The water pump spindle threads for the cooling fan and fan clutch assembly are left hand threads hence 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.



    Water pump with a new gasket. Tighten the M6 bolts to 78 inch lbs. (9 Nm), and the M8 bolts to 16 ft. lbs. (22 Nm).
     
    Thermostat and thermostat housing onto the water pump assembly using a new housing gasket sealing ring
     
    Crankshaft pulley vibration damper using new fasteners. Be sure to align the damper with the dowel.
     
    Water pump pulley onto the water pump
     
    Accessory drive belts
     
    Cooling fan and fan clutch assembly onto the threaded water pump spindle
     



    Fan clutch assembly using tool No. 11-5-040. Nut: 29 ft. lbs. (40 Nm). If using the fan tool, torque the nut to 22 ft. lbs. (30 Nm); as the additional length of the tool multiplies the torque to achieve 29 ft. lbs. (40 Nm) at the nut.
     

  4.  
  5. The remaining components are installed in the reverse order from which they were removed.
  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
    NOTE
    It may be necessary to bleed the cooling system a second time once the engine has been started.

  10.  

  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 cable
     
    Engine splash shield
     
    Radiator
     
    Nut holding the transmission oil cooler lines to the engine oil pan, if equipped
     
    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
     

  10.  
  11. Installation is the reverse of the removal procedure. When installing the engine, place the mount stud in hole (1) of the support bracket. Use 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)

    Click image to see an enlarged view

    Fig. Engine front lift point



    Click image to see an enlarged view

    Fig. Engine rear lift point



    Click image to see an enlarged view

    Fig. During installation on M62 and S62 engines, place mount stud in hole (1) of the support bracket

     

  12.  

M73 Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The water pump can be separated from the engine by using 3 M6 bolts threaded into the tapped bores of the water pump housing. To press the water pump away from the engine thread the bolts evenly.



    Negative battery cable
     
    Air filter housing electrical connector
     
    Air inlet hose
     
    Mass Air Flow (MAF) sensor
     
    Cooling fan and fan clutch
     
    Oil filler cap drip tray
     
    Non-return valve pressure hoses
     
    Coolent vent hose bracket
     
    Cylinder 1-6 non-return valve
     
    Pressure pipe
     
    Left side heat baffle from the front axle support
     
    Coolant from the radiator and the engine block drain
     
    Cooling system reservoir expansion tank
     
    Fan shroud assembly
     
    Air conditioning drive belt
     
    Coolant hoses from the upper water pump housing
     
    Engine coolant expansion tank hose bracket
     
    Electrical connector for the coolant temperature sensor
     
    Fasteners securing the pulley to the water pump
     
    Pump mounting bolts
     
    Water pump assembly
     

  4.  
  5. If replacing the water pump, secure the water pump in a vice. Take care not to damage the housing or gasket mating surfaces. Then remove the coolant temperature sensor, the thermostat housing cover and the thermostat assembly and transfer these parts to the replacement pump using a new thermostat housing gasket sealing ring. It is also suggested to renew the thermostat at this time.
  6.  

To install:

  1. Clean and remove any residual debris or gasket material from the engine mounting surface for the water pump.
  2.  
  3. Install or connect the following:
    NOTE
    The water pump spindle threads for the cooling fan and fan clutch assembly are left hand threads hence 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.



    Lubricate and install new O-rings
     
    If replacing the water pump, coolant temperature sensor, thermostat, and thermostat housing using a new gasket
     
    Water pump. Tighten the M6 bolts to 78 inch lbs. (9 Nm) and the M8 bolts to 16 ft. lbs. (22 Nm).
     
    Coolant temperature sensor electrical connector
     
    Water pump pulley onto the water pump
     
    Cooling fan and fan clutch assembly onto the threaded water pump spindle
     



    Fan clutch assembly using tool No. 11-5-040. Nut: 29 ft. lbs. (40 Nm). If using the fan tool, torque the nut to 22 ft. lbs. (30 Nm); as the additional length of the tool multiplies the torque to achieve 29 ft. lbs. (40 Nm) at the nut.
     

  4.  
  5. The remaining components in the reverse order from which they were removed.
  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
    NOTE
    It may be necessary to bleed the cooling system a second time once the engine has been started.

  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The water pump can be separated from the engine by using 3 M6 bolts threaded into the tapped bores of the water pump housing. To press the water pump away from the engine thread the bolts evenly.



    Negative battery cable
     
    Air filter housing electrical connector
     
    Air inlet hose
     
    Mass Air Flow (MAF) sensor
     
    Cooling fan and fan clutch
     
    Oil filler cap drip tray
     
    Non-return valve pressure hoses
     
    Coolent vent hose bracket
     
    Cylinder 1-6 non-return valve
     
    Pressure pipe
     
    Left side heat baffle from the front axle support
     
    Coolant from the radiator and the engine block drain
     
    Cooling system reservoir expansion tank
     
    Fan shroud assembly
     
    Air conditioning drive belt
     
    Coolant hoses from the upper water pump housing
     
    Engine coolant expansion tank hose bracket
     
    Electrical connector for the coolant temperature sensor
     
    Fasteners securing the pulley to the water pump
     
    Pump mounting bolts
     
    Water pump assembly
     

  4.  
  5. If replacing the water pump, secure the water pump in a vice. Take care not to damage the housing or gasket mating surfaces. Then remove the coolant temperature sensor, the thermostat housing cover and the thermostat assembly and transfer these parts to the replacement pump using a new thermostat housing gasket sealing ring. It is also suggested to renew the thermostat at this time.
  6.  

To install:

  1. Clean and remove any residual debris or gasket material from the engine mounting surface for the water pump.
  2.  
  3. Install or connect the following:
    NOTE
    The water pump spindle threads for the cooling fan and fan clutch assembly are left hand threads hence 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.



    Lubricate and install new O-rings
     
    If replacing the water pump, coolant temperature sensor, thermostat, and thermostat housing using a new gasket
     
    Water pump. Tighten the M6 bolts to 78 inch lbs. (9 Nm) and the M8 bolts to 16 ft. lbs. (22 Nm).
     
    Coolant temperature sensor electrical connector
     
    Water pump pulley onto the water pump
     
    Cooling fan and fan clutch assembly onto the threaded water pump spindle
     



    Fan clutch assembly using tool No. 11-5-040. Nut: 29 ft. lbs. (40 Nm). If using the fan tool, torque the nut to 22 ft. lbs. (30 Nm); as the additional length of the tool multiplies the torque to achieve 29 ft. lbs. (40 Nm) at the nut.
     

  4.  
  5. The remaining components in the reverse order from which they were removed.
  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
    NOTE
    It may be necessary to bleed the cooling system a second time once the engine has been started.

  10.  

N62 Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fan cowl
     
    Alternator drive belt
     
    Connectors and vacuum line holder
     
    Hoses and pulley from water pump
     
    Vibration damper
     
    Water pump fasteners and water pump
     

  6.  
  7. Installation is the reverse of the removal procedure. Note the following:

    Clean and remove any residual debris or gasket material from the engine mounting surface for the water pump
     
    Check for missing or damaged adapter sleeve on the pump
     
    Replace the water pump seals and coolant pipes
     
    Coat the sealing points of the coolant pipes with a rubber coating
     

  8.  

  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. Secure the engine with a holding tool to prevent it from tilting.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Transmission assembly
     
    Radiator and hoses
     
    Expansion tank
     
    Intake manifold
     
    Heater hoses
     
    Engine wiring harness from the control unit
     
    Spark plug wiring harness
     
    Negative lead from spring strut dome
     
    Vacuum line and hose from vacuum pump
     
    Line on tank venting valve
     
    Both oxygen monitor and control sensors
     
    Negative lead from engine support arm
     
    Vibration damper and tensioning pulley fro A/C compressor drive belt
     
    Fasteners from power steering pump, secure pump aside
     
    Fasteners from A/C compressors, secure compressor aside
     
    Fasteners from ABS control unit, secure unit aside
     
    Lower universal joint from the steering spindle
     
    If equipped with Dynamic Drive, unlock and detach the hydraulic line
     
    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
     

  12.  
  13. Installation is the reverse of the removal procedure. Use 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)
     

  14.  

S54 Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Water pump and alternator drive belts
     
    Pulley from water pump
     
    Thermostat
     
    Screws and coolant pipe from the exhaust side of the cylinder head, on 3 series
     
    Water pump fasteners and water pump
     

  6.  
  7. Installation is the reverse of the removal procedure. Note the following:

    Clean and remove any residual debris or gasket material from the engine mounting surface for the water pump
     
    Check for missing or damaged dowel pins on the pump
     
    Replace the water pump seal and cooling pipe O-ring
     

  8.  

S62 Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly discharge the A/C system.
  4.  
  5. Drain the cooling system.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. 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.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Retaining clips from air ducts
     
    Turn duct upwards to unlock, then pull forward and out
     
    Connections on Digital Motor Electronics (DME) control unit
     
    Wiring harness connections in electronics box
     
    Retaining clips from heater bulkheads
     
    Lay engine wiring harness on engine
     
    Oil pressure switch connector
     
    Grounding cable and main flow oil filter housing from holder
     
    Fasteners on right floor panel
     
    Pull floor panel down and disconnect positive battery lead
     
    Release expansion rivet and withdraw positive battery lead from holders
     
    Remove transmission
     
    Alternator drive belt
     
    A/C compressor drive belt and compressor
     
    Power steering pump bolts and secure pump aside
     
    Left side filter housing
     
    Low pressure lead from brake booster
     
    Locks and clips from fuel hose, then the fuel hose
     
    Vacuum line and cooling system hoses
     
    Right exhaust manifold
     
    Ground strap from right engine support
     
    Top left and right nuts from engine mount
     
    Intake manifold cover
     
    Verify that all remaining fluid lines or electrical leads have been disconnected and properly placed aside
     
    Carefully lift the engine from the vehicle
     

  12.  
  13. Installation is the reverse of the removal procedure. When installing the engine, place the mount stud in hole (1) of the support bracket. Use 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)

    Click image to see an enlarged view

    Fig. Engine ground strap and mount

     

  14.  

 
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