BMW Coupes and Sedans 1970-1988 Repair Guide

Engine

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Most engine repair work may be performed with the engine installed in the car. The only operations that should require removal of the engine is camshaft removal, or any extensive cylinder block overhaul.

On all 1600, 2000 and 2002

models, the engine and transmission should be removed as a unit.

Before setting out to tear out your engine, and tying up both yourself and your BMW, there are a few preliminary steps that should be taken. Write down those engine and chassis numbers (see Routine Maintenance ) and make a trip to your parts dealer to order all those gaskets, hoses, belts, filters, etc. (such as the exhaust manifold-to-head pipe flange gasket) that are in need of replacement. This will help avoid last minute or weekend parts dashes that can tie up a car even longer. Also, have enough oil, antifreeze, transmission fluid, etc. (see the Capacities chart) on hand for the job. If the car is still running, have the engine, engine compartment, and underbody steam cleaned. The less dirt, the better. Have all of the necessary tools together. These should include a sturdy hydraulic jack and a pair of jackstands of sufficient capacity, a chain/pulley engine hoist of sufficient test strength, a wooden block and small jack to support the oil pan or transmission, a can of penetrating fluid to help loosen rusty nuts and bolts, a few jars and plastic containers to store and identify used engine hardware, and a punch or bottle of brush paint to matchmark adjacent parts, to aid in reassembly. Once you have all of your parts, tools, and fluids together, proceed with the task.

REMOVAL & INSTALLATION



1600, 2000 and 2002 Models

See Figures 1, 2, 3 and 4

On all 1600, 2000 and 2002

models, the engine and transmission should be removed as a unit.

  1. Open the hood and trace the outline of the hood hinge mounts on the hood.
  2.  
  3. Cover the fenders with protective aprons. With the help of an assistant, remove the hood hinge bolts and lift off the hood. Place the hood away from the work area.
  4.  
  5. Open the draincocks at the bottom of the radiator and the right rear side of the engine block. Drain the cooling system into a suitable container.
  6.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. From under the vehicle, remove the oil pan drain plug, and allow the crankcase oil to drain into a suitable container.
  2.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. From under the vehicle, remove the transmission drain plug, and allow the gear oil or transmission fluid, depending on transmission type to drain into a suitable container.
  2.  
  3. Disconnect the negative battery cable followed by the positive battery cable. Remove the retaining bolt and bracket, and lift the battery out of the engine compartment. Place it aside.
  4.  
  5. Access the air cleaner assembly and tag each hose or vacuum line. Remove the cleaner assembly mounting bolts, vacuum control hose(s), breather hoses and tubes. Lift the air cleaner off and out of the engine compartment.
  6.  
  7. On carburetor equipped models, remove the preheating air regulation housing and hose assembly attached to the front panel.
  8.  
  9. Disconnect the radiator hoses at the thermostat and water pump, tagging each hose as it is being unfastened. On some 2002 models a transmission cooler is incorporated into the radiator. Tag and remove these lines at their radiator connections.
  10.  
  11. Remove the radiator retaining bolts and carefully lift out the radiator.
  12.  
  13. Disconnect the multiple plug from the alternator and tag, and remove the battery main power cable from the alternator and starter. Mark them for reassembly. Tag and disconnect the coolant temperature sensor.
  14.  
  15. Disconnect and tag the throttle linkage.
  16.  
  17. On 2002 models equipped with an automatic choke, disconnect the cable from the choke and the thermo-start valve. Detach the plug from the starter lock and pull the cable loom out of the retainer at the transmission. Detach the coolant hoses from the automatic choke housing.
  18.  
  19. On manual choke equipped models, disconnect the choke cable from the lever and the cable sleeve from the cable clamp and pull out the cable.
  20.  



Click image to see an enlarged view

Fig. Fig. 1: When removing nuts, bolts and other parts, place them in a tray or other container



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Fig. Fig. 2: An example of marked wires using reusable plastic tags



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Fig. Fig. 3: Some wires are disconnected by separating sections of the harness ...



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Fig. Fig. 4: ... while other wires are disconnected at the electrical device

  1. On all 2002 models equipped with the Solex 32 DIPTA model carburetor, disconnect and tag the wire for the electric choke, and the leads for the EGR system. If equipped with downshift linkage, disconnect the downshift linkage by detaching the clamp spring and return spring, then lifting out the wire retainer and disconnecting the linkage ball. Finally, pull the torsion shaft towards the front of the vehicle.
  2.  
  3. Disconnect and plug the fuel line at the tank side of the fuel pump.
  4.  
  5. On 2002Tii models, disconnect the fuel hose at the injection pump. Remove the main fuel filter from its mount on the front panel. Disconnect the fuel reflow hose. Tag all hoses prior to removal
  6.  
  7. On models equipped with the emission control air pump, disconnect the vacuum line from the check (non-return) valve at the intake manifold.
  8.  
  9. Disconnect the heater hoses at the return flow connection and cylinder head connection.
  10.  
  11. Disconnect and label the wire connector from the oil pressure switch, the distributor primary connection, and the ground strap at the engine transmission flange.
  12.  
  13. On 2002Tii models, disconnect the cable from the thermo-time switch. Disconnect and label the vacuum hose from the air container and the cable from the start valve. Release the cable from the cable clamps on the cam cover.
  14.  
  15. Disconnect the coil high tension lead from the center of the distributor cap.
  16.  
  17. On 2002Tii models, pull out the induction transmitter from the coil.
  18.  
  19. On manual transmission equipped models, remove the shifter by accessing from inside the vehicle the shifter and sliding the boot up along with the foam rubber ring and inner sealing boot. Lift the leaf spring out of the selector head. On models with a pivot-ball on the shift lever end, pull up the rubber boot and gasket to access and remove the snapring and shift lever.
  20.  
  21. On automatic transmission equipped models, Remove the shifter plate retaining screws and lift the plate up and unfasten the shift rod snapring from the transmission assembly. Disconnect the reverse light neutral start switch lead.
  22.  
  23. Using a hydraulic floor jack of sufficient weight capacity, raise the front of the car, and position jackstands beneath the reinforced box members adjacent to the 2 front jacking points.
  24.  


CAUTION
Before climbing under the car, make sure that the jackstands are secure.

  1. Disconnect the head pipe from the exhaust manifold. Disconnect the head pipe support and the front muffler mounting hardware.
  2.  
  3. Disconnect the driveshaft from the transmission flange by releasing the self-locking nuts and bolts from the giubo coupler. Tie up the drive shaft so that it does not fall on you as you work.
  4.  
  5. Disconnect the reverse light wires from their terminals, and the speedometer cable from the transmission.
  6.  
  7. On 2002 models, remove the hydraulic line bracket from the clutch housing, but do not disconnect the line from the slave cylinder. Disconnect the return spring from the throwout lever. Pull back the dust cover and remove the snap-ring from the slave cylinder. Then pull the slave cylinder forward and remove the pushrod.
  8.  
  9. On 1600 models, detach the pullrod on the intermediate shaft. Detach the bearing support from the engine support. Then remove the intermediate shaft.
  10.  
  11. Support the weight of the transmission with a floor jack and a block or wood. Attach lifting eyes to strong mounting points at the front and rear of the engine. Hook up an engine hoist to the eyelets and take the slack out of the host chain.
  12.  
  13. Remove the left and right-hand engine mount bolts. Remove the bolts retaining the driveshaft center support bearing to the body. Remove the C-bolts for the transmission support crossmember.
  14.  
  15. The engine/transmission unit should now be free. Check to make sure that all wires, hoses, etc. are disconnected. Remove the windshield washer reservoir for additional removal clearance.
  16.  
  17. Carefully, tilt the transmission down and the front of the engine up. Lift the engine out with the front raised higher than the transmission. With the engine raised above the top of the fenders, lower the car, and push back from under the engine. With the engine/transmission clear of the car, lower the engine onto a stand, workbench, or other suitable sturdy work surface.
  18.  

To install:
  1. Reverse the above procedure to install using the following installation notes:
    1. When bolting the engine of the 1600, 2002, and 2002 models with an automatic transmission, make sure that the right engine mount support stop is adjusted so that a 0.11 inches (3mm) clearance exists.
    2.  
    3. When installing the center driveshaft support bearing mount, preload the bearing mount by adjusting it forward 0.08 inches (2mm) in its eccentric bolt holes. Make sure that the driveshaft bolts are tightened to 22 ft. lbs. (29 Nm).
    4.  
    5. When connecting the pullrod to the intermediate shaft, make sure that the bearing support is aligned at a 90° angle to the engine before tightening the mounting screws.
    6.  
    7. When hooking up the exhaust system, make sure to follow this sequence: first connect the head pipe to the manifold, then loosen the head pipe support mount on the transmission so that it rests tension-free against the pipe, then tighten the support mount on the transmission and finally tighten the support bracket on the head pipe.
    8.  
    9. Adjust the clutch free-play while the car is up in the air. Refer to Drive Train for details.
    10.  
    11. When installing the shift lever, make sure that the gearshift pin is installed in its lever with the bolt positioned in the centering recess of the pin. Also make sure that the breather holes in the shifter dust boot face downward.
    12.  
    13. When filling the radiator, make sure that the heater control is set to the HOT position.
    14.  
    15. When hooking up the choke on 1970-71 1600, 2000 and 200 models, make sure that the choke handle on the dash is at its bottom notch. Then press the fast idle lever against the stop, and tighten the clamp screw. The sleeve must project exactly 0.6 inches (15mm) for the choke flap to close fully.
    16.  
    17. Before starting the car, make sure all hoses, vacuum lines and wires are connected securely, and will not rub against other parts of the engine or body and short circuit.
    18.  

  2.  

2500, 2800, Bavaria and 3000 Carbureted Models

The transmission should be separated from the block prior to engine removal.

  1. Scribe alignment marks on the hood hinges, then remove the hood.
  2.  
  3. Disconnect and remove the battery.
  4.  
  5. Remove the air cleaner and hoses.
  6.  
  7. Drain the cooling system, disconnect and tag the hoses. Remove the radiator from the vehicle.
  8.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the windshield washer reservoir and blower fan fan. Tag all connections
  2.  
  3. Disconnect and tag the wiring from all engine electrical devices including electric choke and control sensor units.
  4.  
  5. Unfasten the main power wires to the alternator and starter. Tag and remove the control harness from each.
  6.  
  7. Disconnect the accelerator linkage.
  8.  
  9. Unbolt the exhaust pipe from the exhaust manifold.
  10.  
  11. Remove the front lower apron and loosen both engine mounting retaining nuts.
  12.  
  13. On vehicles equipped with power steering, remove the pump from the mounting brackets and move the pump out of the way. Tie the pump to the vehicle body using a piece of wire. Do not knink the hoses.
  14.  
  15. Raise and support the vehicle safely on jackstands
  16.  
  17. Remove the locknuts and bolts securing the flexible giubo coupler to the transmission and driveshaft. Separate the driveshaft on tie out of the way using a piece of wire.
  18.  
  19. On manual transmission cars, remove the slave cylinder from the clutch housing, leaving the hose attached.
  20.  
  21. From underneath the vehicle, remove the transmission retaining hardware and free the transmission from the engine. Lower the transmission down and move aside. Refer to Drive Train for transmission removal procedures.
  22.  
  23. Lower the car and attach a lifting sling to the engine.
  24.  
  25. Be sure that all wires, hoses and linkages are disconnected and out of the way.
  26.  
  27. To remove the engine, begin by angling the engine up towards the front of the vehicle, then out of the engine compartment.
  28.  
  29. Place the engine on a strong surface to perform any needed work.
  30.  

To install:
  1. Install the engine assembly into the vehicle. Be careful to position the engine correctly in the engine mount locations.
  2.  
  3. Once the engine is securely in its mounts, loosely install the mount retaining nuts.
  4.  
  5. Raise and safely support the vehicle on jackstands.
  6.  
  7. Install the transmission giubo coupler and driveshaft on the engine, being careful to align it with the engine. Refer to Drive Train for installation details.
  8.  
  9. After the transmission and driveshaft assemblies are secured to the engine, tighten the engine mount nuts. Remove the lifting device from the engine and lower the vehicle to the ground.
  10.  
  11. On manual transmission equipped vehicles, install the clutch slave cylinder to the transmission housing.
  12.  
  13. Install the power steering pump to the brackets, if equipped.
  14.  
  15. Reconnect the exhaust pipe to the exhaust manifold.
  16.  
  17. Install the accelerator linkage and all electrical wiring and hoses to the engine.
  18.  
  19. Install the windshield reservoir and the cooling fan.
  20.  
  21. Position and fasten the air cleaner assembly and hoses.
  22.  
  23. Install the front lower apron.
  24.  
  25. Connect the battery cables, positive first then negative.
  26.  
  27. Install the hood, aligning the scribe marks made during disassembly.
  28.  

3.0 Models

When removing the engine from this model, automatic transmission assemblies should be remove prior to engine removal. Manual transmission assemblies can be removed with the engine.

  1. Open the hood and trace the outline of the hood hinge mounts on the hood.
  2.  
  3. Cover the fenders with protective aprons. With the help of an assistant, remove the hood hinge bolts and lift off the hood. Place the hood away from the work area.
  4.  
  5. Disconnect the negative battery cable followed by the positive cable.
  6.  
  7. Open the draincocks at the bottom of the radiator and the right rear side of the engine block. Drain the cooling system into a suitable container.
  8.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. From under the vehicle, remove the oil pan drain plug, and allow the crankcase oil to drain into a suitable container.
  2.  


CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.

  1. From under the vehicle, remove the transmission drain plug, and allow the gear oil or transmission fluid, depending on transmission type to drain into a suitable container.
  2.  
  3. Disconnect the main power wires from the battery to the alternator and starter. Unfasten the multiple wire connectors at each unit. Tag prior to removal.
  4.  
  5. Access the air cleaner assembly and tag each hose or vacuum line. Remove the cleaner assembly mounting bolts, vacuum control hose(s), breather hoses and tubes. Lift the air cleaner off and out of the engine compartment.
  6.  
  7. Disconnect the radiator hoses at the thermostat and water pump, tagging each hose as it is being unfastened. On some models a transmission cooler is incorporated into the radiator. Tag and remove these lines at their radiator connections.
  8.  
  9. Remove the radiator retaining bolts and carefully lift out the radiator.
  10.  
  11. Disconnect the multiple plug from the alternator and tag, and remove the battery main power cable from the alternator and starter. Mark them for reassembly. Tag and disconnect the coolant temperature sensor.
  12.  
  13. Separate the electrical connection for the fuel injection wire loom by removing the 3 retaining screws.
  14.  
  15. Remove the wire leads from the relays, sensors, and switches. Mark the wire connections for installation.
  16.  
  17. Disconnect and tag the throttle linkage.
  18.  
  19. On models equipped with the emission control air pump, disconnect the vacuum line from the check (non-return) valve at the intake manifold.
  20.  
  21. Disconnect the heater hoses at the return flow connection and cylinder head connection.
  22.  
  23. Disconnect and label the wire connector from the oil pressure switch, the distributor primary connection, and the ground strap at the engine transmission flange.
  24.  
  25. Disconnect the cable from the thermo-time switch. Disconnect and label the vacuum hose from the air container and the cable from the start valve. Release the cable from the cable clamps on the cam cover.
  26.  
  27. Disconnect the coil high tension lead from the center of the distributor cap.
  28.  
  29. Pull out the induction transmitter from the coil.
  30.  
  31. On manual transmission equipped models, remove the shifter by accessing it from inside the vehicle. Slide the shifter and sliding the boot up along with the foam rubber ring and inner sealing boot. Lift the leaf spring out of the selector head. On models with a pivot-ball on the shift lever end, pull up the rubber boot and gasket to access and remove the snapring and shift lever.
  32.  
  33. On automatic transmission equipped models, Remove the shifter plate retaining screws and lift the plate up and unfasten the shift rod snapring from the transmission assembly. Disconnect the reverse/neutral start switch lead.
  34.  
  35. Using a hydraulic floor jack of sufficient weight capacity, raise the front of the car, and position jackstands beneath the reinforced box members adjacent to the 2 front jacking points.
  36.  


CAUTION
Before climbing under the car, make sure that the jackstands are secure.

  1. Disconnect the head pipe from the exhaust manifold. Disconnect the head pipe support and the front muffler mounting hardware.
  2.  
  3. Disconnect the driveshaft from the transmission flange by releasing the self-locking nuts and bolts from the giubo coupler. Tie up the drive shaft so that it does not fall on you as you work.
  4.  
  5. Disconnect the speedometer cable from the transmission.
  6.  
  7. Remove the hydraulic line bracket from the clutch housing, but do not disconnect the line from the slave cylinder. Disconnect the return spring from the throwout lever. Pull back the dust cover and remove the snap-ring from the slave cylinder. Then pull the slave cylinder forward and remove the pushrod.
  8.  
  9. Support the weight of the transmission with a floor jack and a block of wood. Attach lifting eyes to strong mounting points at the front and rear of the engine. Hook up an engine hoist to the eyelets and take the slack out of the host chain.
  10.  
  11. On automatic equipped models, remove all retaining hardware securing the transmission to the engine. Refer to Drive Train for details. Lower the automatic transmission down and away from the vehicle.
  12.  
  13. Remove the left and right-hand engine mount bolts.
  14.  
  15. The engine and transmission unit, if equipped with a manual transmission, should now be free. Check to make sure that all wires, hoses, etc. are disconnected. Remove the windshield washer reservoir for additional removal clearance.
  16.  
  17. Carefully, tilt the transmission down and the front of the engine up. Lift the engine out with the front raised higher than the transmission. With the engine raised above the top of the fenders, lower the car, and push back from under the engine. With the engine/transmission clear of the car, lower the engine onto a stand, workbench, or other suitable sturdy work surface.
  18.  

To install:
  1. Install the engine assembly into the vehicle. Be careful to position the engine correctly in the engine mount locations.
  2.  
  3. Once the engine is securely in its mounts, loosely install the mount retaining nuts.
  4.  
  5. Raise and safely support the vehicle on jackstands.
  6.  
  7. Install the transmission engine, being careful to align it with the engine. Refer to Drive Train for installation details.
  8.  
  9. When installing the center driveshaft support bearing mount, preload the bearing mount by adjusting it forward 0.08 inches (2mm) in its eccentric bolt holes. Make sure that the driveshaft bolts are tightened to 22 ft. lbs. (29 Nm).
  10.  
  11. Install the shift lever making sure that the gearshift pin is installed in its lever with the bolt positioned in the centering recess of the pin. Also make sure that the breather holes in the shifter dust boot face downward.
  12.  
  13. After the transmission and driveshaft assemblies are secured to the engine, tighten the engine mount nuts. Remove the lifting device from the engine and lower the vehicle to the ground.
  14.  
  15. On manual transmission equipped vehicles, install the clutch slave cylinder to the transmission housing.
  16.  
  17. Reconnect the exhaust pipe to the exhaust manifold.
  18.  
  19. Install the accelerator linkage and all electrical wiring and hoses to the engine.
  20.  
  21. Position and fasten the air cleaner assembly and hoses.
  22.  
  23. Connect the battery cables positive first, then negative.
  24.  
  25. Install the hood, aligning the scribe marks made during disassembly.
  26.  
  27. Before starting the car, make sure all hoses, vacuum lines and wires are connected securely, and will not rub against other parts of the engine or body and short circuit.
  28.  

318i Models

See Figures 5, 6 and 7

The transmission must be separated from the block prior to engine removal.

  1. Scribe hood hinge locations on the hood, and then remove.
  2.  
  3. Disconnect the negative battery cable, followed by the positive cable.
  4.  
  5. Raise and safely support the vehicle on jackstand.
  6.  
  7. Remove the transmission assembly as detailed in Drive Train .
  8.  
  9. Detach the 2 mounting bolts and remove the power steering pump with the hoses attached. Suspend the pump securely with a piece of wire so that hoses will not be damaged.
  10.  
  11. Looking at the top of the air conditioning compressor, loosen the 2 outer bolts (bolts screwed into the compressor) and remove the 2 bolts fastening the mounting bracket to the engine. Then, support the unit and remove the hinge nut and bolt form the bottom of the unit. Finally, pull the unit away from the engine and support it with wire to avoid putting strain on refrigerant hoses.
  12.  

Do not disconnect any air conditioning hoses!



Click image to see an enlarged view

Fig. Fig. 5: To remove the A/C compressor, remove bolts 1 and 2. Then unfasten the bolts at the base of the compressor



Click image to see an enlarged view

Fig. Fig. 6: Tag and disconnect wires 3 and 5, then tag and unplug wires 6 and 7



Click image to see an enlarged view

Fig. Fig. 7: Disconnect wire 12, then lift off cap 13 and remove the relay 14. Unfasten plug 15, open the hose clamp 16 and loosen the nuts 17

  1. Remove the radiator cap and drain the coolant. Detach and tag the radiator hoses. On air conditioned equipped models, disconnect the wires at the temperature switches. Unscrew and remove the cover located at the left side of the radiator (driver's side). Unscrew and disconnect transmission oil cooler lines at the radiator (automatic only), and plug the openings. Finally, remove the mounting bolt located at the top of the radiator and lift the radiator upward until it clears the rubber mounts on the bottom, and remove it.
  2.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the battery-to-alternator and stater wires, as well as the control harness for each. Disconnect the engine ground strap.
  2.  
  3. Open the clips that hold the wiring harness running along the fender just behind the battery. Disconnect the plugs from the temperature sensor and oxygen sensor. Tag prior to removal.
  4.  
  5. Remove the glovebox liner. Unplug the connectors at the idle control and L-Jetronic units. Unplug the connector that also comes out of this harness. Then, pull the harness through the rubber grommet into the engine compartment.
  6.  
  7. Tag and disconnect the coil wires and wire to the electronic ignition unit. Take the wires out of the clips mounted nearby.
  8.  
  9. At the air cleaner, disconnect the wire mounted on the side of the air cleaner housing, and disconnect the plug. Lift off the L-shaped cap for the relay mounted nearby, then remove the relay. Loosen the strap and disconnect the inlet hose.
  10.  
  11. Loosen the 2 mounting nuts and remove the air cleaner assembly.
  12.  
  13. Access the relay box mounted in between the cowl and suspension strut on the driver's side. Remove the top of the box and lift out and disconnect the plug on the outboard side. Remove the rubber guard for the control unit nearby and pull off the plug connected to it.
  14.  
  15. From the rear of the intake manifold, unscrew the clamp and pull off the large vacuum hose. Label and then disconnect the small vacuum hoses running to the distributor and intake manifold.
  16.  
  17. Disconnect the throttle cable. Remove the hose clamp and hose nearby.
  18.  
  19. Detach the fuel hoses at the injection system. Capture any spilled fuel with a rag or in a metal pan.
  20.  
  21. Attach a suitable hoist to the engine hooks at the front and rear of the engine and support the engine securely.
  22.  
  23. Detach both engine mounts.
  24.  
  25. Unbolts the locknuts and bolts securing the giubo coupler and driveshaft. Separate the driveshaft from the transmission and secure in place with wire.
  26.  
  27. Remove the transmission retaining bolts and separate the transmission from the engine. Lower and place aside. Refer to Drive Train for details.
  28.  
  29. Lift out the engine, taking care not to permit the engine to shift and hit anything on the way out.
  30.  

To install:
  1. Lower the engine into place making sure the locating mandrel on the front of the engine is guided into the front suspension carrier. Install the engine mount retainer nuts and tighten to 31-35 ft. lbs. (40-47 Nm) .
  2.  
  3. Position the transmission under the vehicle and lift into place. Secure with retaining hardware. Refer to Drive Train for details.
  4.  
  5. Attach the giubo coupler and driveshaft to the transmission.
  6.  
  7. Connect the fuel lines using new hose clamps to connect the fuel lines to the fuel filter. Connect all of the multi-prong plugs and all vacuum hoses.
  8.  
  9. Connect the accelerator cable and adjust.
  10.  
  11. Install the radiator hoses using new hose clamps if needed.
  12.  
  13. Install the air cleaner and reconnect all electrical plugs. Connect and install the relays in the relay box.
  14.  
  15. Reconnect the wiring to the main control unit and install the idle control unit running the harnesses into the interior of the vehicle. Make sure the rubber grommet is seated correctly.
  16.  
  17. Install the air conditioning compressor and power steering pump.
  18.  
  19. Connect the alternator and starter wires.
  20.  
  21. Connect the battery cables, positive first, then negative.
  22.  
  23. Install the hood and align if needed.
  24.  
  25. Make sure all fluid levels are correct before starting the engine. Bleed air from the cooling system.
  26.  

1977-79 320i Models

The transmission must be separated from the block prior to engine removal.

  1. Disconnect the negative battery cable, followed by the positive cable.
  2.  
  3. Raise and support the vehicle on jackstands.
  4.  
  5. Remove the transmission. Refer to Drive Train for details. Disconnect the exhaust pipe from the exhaust manifold.
  6.  
  7. Remove the hood, after scribing the hinge locations.
  8.  
  9. Drain the cooling system, disconnect the hoses and remove the radiator. Remove the intake air panel.
  10.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Tag and disconnect the lines to the injector valves.
  2.  
  3. Disconnect all electrical wires from the engine, marking them for installation.
  4.  
  5. Disconnect the main wires and control wires for both the starter and alternator. Mark prior to removal.
  6.  
  7. Disconnect all fuel and vacuum lines and mark them for installation.
  8.  
  9. Disconnect the accelerator cable.
  10.  
  11. Attach a lifting sling to the engine lifting eyes. Remove the retaining nuts from the left and right engine mounts and the upper engine damper.
  12.  
  13. Carefully raise and remove the engine from the vehicle.
  14.  

To install:
  1. Install the engine into the engine compartment, aligning the motor mounts in their appropriate position. Install the motor mount retaining nuts and install the upper engine damper.
  2.  
  3. Connect all of the electrical wiring, including starter and alternator.
  4.  
  5. Connect the fuel lines and vacuum hoses.
  6.  
  7. Install the radiator and connect all hoses.
  8.  
  9. Install the air intake panel.
  10.  
  11. Connect the exhaust pipe to the exhaust manifold.
  12.  
  13. Raise and safely support the vehicle and install the transmission, carefully aligning it with the engine.
  14.  
  15. Connect the battery cables positive first, then negative.
  16.  
  17. With the aid of a helper, install the hood aligning the scribe marks made before removing the engine.
  18.  
  19. Before starting the vehicle, add anti-freeze and bleed the cooling system. Check all fluids to make sure their levels are satisfactory.
  20.  

1980-83 320i Models

The transmission must be separated from the block prior to engine removal.

  1. Remove the transmission as detailed in Drive Train .
  2.  
  3. Scribe lines around the hood hinges and remove the hood.
  4.  
  5. Disconnect the upper and lower radiator hoses and then remove the radiator.
  6.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Unscrew and remove the air filter housing from the engine compartment.
  2.  
  3. On models equipped with air conditioning, detach the compressor and position it out of the way with the wires attached. Do not disconnect the refrigerant lines. Use a piece of wire to secure the compressor so the lines do not bend.
  4.  
  5. Disconnect the battery cables (negative cable first) and remove the battery.
  6.  
  7. Disconnect all fuel lines at the fuel distributor. Pull the hose off the charcoal canister.
  8.  
  9. Disconnect the ground wire form the front axle carrier.
  10.  
  11. Unscrew the retaining nut and lift the accelerator cable from the holders toward the side. Push the nipple out toward the rear and then disconnect the cable.
  12.  
  13. Tag and disconnect all remaining wires and hoses which may interfere with engine removal.
  14.  
  15. Lift out the relay socket and then pull out the 2 relays to the side of the housing. Disconnect the plug underneath and then lift out the wire harness from the holder on the wheel arch.
  16.  
  17. Open the glove box and disconnect the control unit plug on the left-hand side. Pull the harness out through the hole in the firewall (into the engine compartment) Pull the harness out of its holders.
  18.  
  19. Attach an engine hoist to the front and rear of the engine.
  20.  
  21. Unbolt the left engine mount and the upper engine damper.
  22.  
  23. Unbolt the right engine mount and lift out the engine.
  24.  

To install:
  1. Install the engine into the engine compartment and install the motor mount nuts.
  2.  
  3. Slide the electrical harness in through the firewall and connect it to the control unit.
  4.  
  5. Connect all the wires and hoses to the engine components, making sure to properly route the wiring.
  6.  
  7. Install the accelerator cable and its retaining nut. When installing the accelerator cable, push the cable through the eye on the lever, attach it and then press the nipple into the eye. Attach the cable to the holder.
  8.  
  9. Connect the fuel lines and the vacuum lines. Install the radiator and connect the hoses.
  10.  
  11. On models equipped with air conditioning install the compressor and connect the wiring.
  12.  
  13. Install the air filter housing.
  14.  
  15. Connect the wires to the starter and alternator.
  16.  
  17. Fill the coolant system with clean anti-freeze and bleed. Check the other fluid levels and adjust if needed.
  18.  
  19. Connect the battery cables, positive fist, then negative.
  20.  
  21. With the aid of an assistant, install the hood, aligning the scribe marks made on the hood.
  22.  

1983-87 325, 325e, 325i, 325iS and 1988 325iX Models

See Figures 8 through 28

The transmission must be separated from the block prior to engine removal.

  1. Disconnect the battery ground cable. Remove the transmission. Refer to Drive Train for details. Unfasten the engine splash guard at the front bottom of the engine.
  2.  
  3. Disconnect the gas spring and prop rod and support hood safely in the fully open position.
  4.  
  5. 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.
  6.  
  7. Hold the fan pulley while unscrewing the fan nut from the shaft. The shaft uses left hand threads; turn the nut counterclockwise to unscrew.
  8.  
  9. Drain the coolant from the engine block. Disconnect the bottom hose from the radiator expansion tank, the engine coolant hoses and finally the heater hoses from the splash wall. When empty, remove the radiator from the vehicle.
  10.  



Click image to see an enlarged view

Fig. Fig. 8: Remove the fan shroud from the back of the radiator



Click image to see an enlarged view

Fig. Fig. 9: Remove the fan from the pulley-remember the fan retainers use left-hand threads



Click image to see an enlarged view

Fig. Fig. 10: Remove the radiator expansion tank hose



Click image to see an enlarged view

Fig. Fig. 11: Loosen the clamp for both radiator hoses and remove-top hose shown



Click image to see an enlarged view

Fig. Fig. 12: Disconnect any wires or harnesses attached to the radiator



Click image to see an enlarged view

Fig. Fig. 13: With all connections and hardware removed, lift the radiator out of the engine compartment



Click image to see an enlarged view

Fig. Fig. 14: Unplug the air-flow sensor harness


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. 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.
  2.  
  3. Unclip the throttle cable and pull the cable out with the rubber holder.
  4.  
  5. Disconnect the fuel lines taking note of their positions. Pull off the vent hose to the filter for tank venting.
  6.  



Click image to see an enlarged view

Fig. Fig. 15: Disconnect the distributor cap and place on top of the engine



Click image to see an enlarged view

Fig. Fig. 16: If equipped with a crank sensor, unclip and place aside



Click image to see an enlarged view

Fig. Fig. 17: Unfasten the idle control plug



Click image to see an enlarged view

Fig. Fig. 18: Unfasten the throttle linkage



Click image to see an enlarged view

Fig. Fig. 19: Remove the air intake hose attached to the throttle body



Click image to see an enlarged view

Fig. Fig. 20: Disconnect the throttle sensor harness



Click image to see an enlarged view

Fig. Fig. 21: Unfasten any remaining harnesses including coolant and fuel sensor

  1. Disconnect the vacuum fitting at the brake booster.
  2.  
  3. Remove the distributor cap and ignition leads from the coil.
  4.  
  5. Unscrew the connections at the alternator and starter. Disconnect the 2 plugs from the electrical duct.
  6.  
  7. 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.
  8.  
  9. 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. Unfasten the oil pressure switch electrical connection.
  10.  
  11. Unscrew the front and rear intake manifold supports.
  12.  
  13. Remove the electrical duct from the engine. Disconnect the coolant temperature senders for the gauge and the DME control unit, if equipped.
  14.  
  15. Disconnect the electrical duct and wiring harness on the engine and lay it off to the side.
  16.  



Click image to see an enlarged view

Fig. Fig. 22: To remove some hoses, the clamps securing them in place will have to be cut off



Click image to see an enlarged view

Fig. Fig. 23: With the clamp removed, slide the hose off



Click image to see an enlarged view

Fig. Fig. 24: When removing numerous hoses from a given area, tag each hose



Click image to see an enlarged view

Fig. Fig. 25: Remove the clutch cover plate from the lower portion of the engine/transmission



Click image to see an enlarged view

Fig. Fig. 26: With the bolts removed, the cover plate can be slid down and away from the engine



Click image to see an enlarged view

Fig. Fig. 27: Removing the exhaust hanger will allow play in the exhaust-this will aid component removal



Click image to see an enlarged view

Fig. Fig. 28: Loosen the front engine mount from under the engine

  1. Use a suitable lifting tool and attach to the engine lifting eyes. Unscrew the motor mounts and the engine ground strap. Lift out the engine.
  2.  

To Install:
  1. Lower the engine into the 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 wiring. Attach the ignition leads to the coil and install the distributor cap.
  10.  
  11. Refit the vacuum connection to the brake booster. Reconnect the tank vent hose and the fuel hoses.
  12.  

The upper fuel hose is the return line and the bottom is the feed line.

  1. Attach the throttle cable and its holder.
  2.  
  3. Replace the air cleaner and air flow meter assembly. Attach the electrical connector to the air flow meter.
  4.  
  5. Connect the heater hoses, engine coolant hoses and the radiator expansion tank hose.
  6.  
  7. Install the fan tightening the nut to 29 ft. lbs. (40 Nm).
  8.  
  9. Replace the fan cowl taking care to engage the tabs at the right and left.
  10.  
  11. Replace the splash guard and the transmission. Reconnect the hood prop rod and gas spring.
  12.  
  13. Add the proper coolant mixture and bleed the cooling system. Check all other fluid levels and adjust if needed.
  14.  
  15. Connect the battery leads and check all fluid levels before starting the engine.
  16.  

1988 325, 325e, 325i and 325iS Models

The transmission must be separated from the block prior to engine removal.

  1. Disconnect the battery ground cable.
  2.  
  3. Remove the transmission as outlined in Drive Train .
  4.  
  5. Remove the engine splash guard below the front bumper.
  6.  
  7. Support hood safely in the fully open position.
  8.  


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

  1. 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.
  2.  
  3. Disconnect the air conditioner compressor without removing the lines. Secure to the vehicle body with a piece of wire.
  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.
  8.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. 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.
  2.  
  3. Remove the air intake duct and disconnect the idle speed control hose. Disconnect the wire holders from the duct.
  4.  
  5. Unbolt the power steering reservoir. Unbolt the power steering pump and support with a piece of wire. Do not bend or kink the hoses.
  6.  
  7. Unscrew the throttle body holder bracket and disconnect the cable from the linkage.
  8.  
  9. Mark the locations of the fuel feed and return hoses. The upper hose is the return line. Disconnect the hoses and plug.
  10.  
  11. Disconnect the vacuum line from the brake booster. Plug the opening to prevent dirt from entering.
  12.  
  13. Remove the grille 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.
  14.  
  15. Disconnect the wiring from the alternator and the starter.
  16.  
  17. Disconnect the cylinder ID sensor and the pulse sender located just behind the oil filter housing.
  18.  
  19. Disconnect the idle speed control and remove from the holder.
  20.  
  21. Disconnect the throttle position sensor lead, oil pressure sender and the tank venting valve connector.
  22.  
  23. Unbolt the fuel line holder and the intake manifold support. Loosen the clamp holding the pipe to the intake support.
  24.  
  25. 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.
  26.  
  27. Disconnect the coolant hose from the transfer pipe on the side of the engine.
  28.  
  29. Connect an engine lifting tool to the lifting tabs at the front and rear of the engine and take up any slack.
  30.  
  31. Disconnect the ground strap and motor mounts.
  32.  
  33. Remove the engine.
  34.  

To install:
  1. Install the engine in the vehicle. Connect the ground strap and tighten the engine mounts to 30 ft. lbs. (42 Nm).
  2.  
  3. Connect the coolant hose to the transfer pipe.
  4.  
  5. Replace the injector electrical lead duct and connect the injectors.
  6.  
  7. Replace the electric lead duct on the intake support and install the intake support.
  8.  
  9. Connect the temperature sensors under the intake manifold.
  10.  
  11. Attach the fuel line holder.
  12.  
  13. Connect the tank venting valve, the throttle position sender, the oil pressure switch and the idle speed control.
  14.  
  15. Install the idle speed control in its holder. Connect the cylinder ID sender and the pulse sender.
  16.  
  17. Connect the starter and alternator.
  18.  
  19. Install the air cowl, bracket and grill.
  20.  
  21. Connect the brake booster vacuum line and the fuel hoses.
  22.  

The upper hose is the fuel return line.

  1. Connect the throttle cable and holder bracket.
  2.  
  3. Install the power steering pump and reservoir.
  4.  
  5. Install the air intake duct and the air cleaner assembly. Connect the idle speed line and the electrical leads. Connect the air flow sensor.
  6.  
  7. Connect the coolant hoses. Install the fan, fan cowl and the air conditioner compressor.
  8.  
  9. Install the hood.
  10.  
  11. Install and transmission referring to Drive Train for details.
  12.  
  13. Install the splash guard and fill the engine fluids.
  14.  
  15. Connect the battery, start the car, bleed the coolant system and check for any fluid leaks.
  16.  

M3 Models

See Figure 29

The transmission must be separated from the block prior to engine removal.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the transmission as outlined in Drive Train .
  4.  
  5. Remove the splash guard from underneath the engine.
  6.  
  7. Put a drain pan underneath and then drain coolant from both the radiator and engine block.
  8.  



Click image to see an enlarged view

Fig. Fig. 29: Loosen the 3 arrowed nuts to remove the A/C compressor


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. 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 assembly.
  2.  
  3. Disconnect the accelerator and cruise control cables. Unscrew the nuts mounting the cable housing mounting bracket and set the housings and bracket aside.
  4.  
  5. Loosen the clamp and disconnect the brake booster vacuum hose.
  6.  
  7. Loosen the clamp and disconnect the other end of the booster vacuum hose at the manifold. Remove the nut from the intake manifold brace.
  8.  
  9. 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 intake assembly.
  10.  
  11. Place a drain pan underneath and loosen the hose clamps and disconnect the coolant expansion tank hoses.
  12.  
  13. Disconnect the engine ground strap.
  14.  
  15. Disconnect the ignition coil high tension lead.
  16.  
  17. Label and disconnect the plugs from the rear of the alternator.
  18.  
  19. Remove the cover for the electrical connectors from the starter. Label the leads and then remove the attaching nuts and disconnect them.
  20.  
  21. 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.
  22.  
  23. 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.
  24.  
  25. There is a vacuum hose connected to the throttle neck. Disconnect it and pull it out of the intake manifold bracket. Pull off the electrical harness. Pull out the rubber retainer, and then remove the idle speed control.
  26.  
  27. 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.
  28.  
  29. Loosen the clamp, then disconnect the PCV hose.
  30.  
  31. Label and then disconnect the fuel lines connecting the injector circuit.
  32.  
  33. Put a drain pan underneath then disconnect the heater hose from the cylinder head.
  34.  
  35. Loosen the clamp near the throttle necks and then pull the engine wiring harness out and put aside.
  36.  
  37. Loosen the mounting clamp for the carbon canister, slide it out of the clamp, and place it aside with the hoses still connected.
  38.  
  39. Note the routing of the oil cooler lines where they connect at the base of the oil filter. Label them if necessary. Put a drain pan underneath and unscrew the flared connectors for the lines.
  40.  
  41. Unbolt and remove the fan. Remove the radiator from the engine compartment.
  42.  
  43. Support the power steering pump. Remove the adjusting bolt, and secure it with a piece of wire. Do not kink the hoses.
  44.  
  45. Remove the adjusting bolt for the air conditioning compressor, then, remove the nut at one end of the hinge bolt and pull the bolt out, suspending the compressor. Secure the compressor to the vehicle body using a piece of wire.
  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 left and bottom right. Then, carefully lift the engine out of the compartment, avoiding contact between the engine and the components remaining in the vehicle.
  48.  

To install:
  1. Keep these points in mind during installation:
    1. Tighten the engine mounting bolts to 32 ft. lbs. (44 Nm).
    2.  
    3. Adjust the belt tension for the air conditioning compressor and power steering pump drive belts to give 0.5-0.7 inch (13-18mm) deflection.
    4.  
    5. Tighten 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. Tighten the mounting nuts to 6 ft. lbs. (9 Nm).
    8.  

  2.  
  3. Reverse the procedures used for removal.
  4.  
  5. Lower the engine into the engine compartment. When the engine is positioned, the guide pin must fit in the bore of the axle carrier. Tighten 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).
  6.  
  7. Install the intake manifold assembly and connect the fuel lines, using new hose clamps, if needed, to connect the fuel lines to the fuel filter.
  8.  
  9. Connect all of the multi-prong plugs and vacuum hoses.
  10.  
  11. Connect the accelerator cable and cruise control cable to the throttle body and adjust.
  12.  
  13. Install the coolant recovery tank, using a new hose clamp on the coolant expansion tank.
  14.  
  15. Install the air cleaner and reconnect all electrical plugs.
  16.  
  17. Connect and install the relays in the relay box.
  18.  
  19. Reconnect the wiring to the main control unit and install the idle control unit.
  20.  
  21. Install the air conditioning compressor and power steering pump. Properly route the accessory drive belt. Adjust the belt tension.
  22.  
  23. Install the radiator and connect the hoses.
  24.  
  25. Install the transmission referring to Drive Train for details.
  26.  
  27. Make sure all fluid levels are correct before starting the engine. Bleed air from the cooling system.
  28.  

524td Models

The transmission must be separated from the block prior to engine removal.

  1. Remove the transmission as detailed in Drive Train .
  2.  
  3. Remove the adjusting and hinge bolts for the power steering pump and support the pump out of the way with a piece of wire.
  4.  
  5. Remove the adjusting and hinge bolts for the air conditioning compressor and support the compressor out of the way with a piece of wire.
  6.  
  7. Remove the drain plug from the engine block and radiator, and drain the coolant. Remove the radiator from the vehicle.
  8.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the ground wires from the hood. Disconnect the gas pressure hood props and securely prop up the engine hood.
  2.  


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

  1. Disconnect the negative, then positive battery leads.
  2.  
  3. Disconnect the primary electrical connection. Lift off the cover and pull off the plugs. Disconnect the wires, and remove the preheating time control.
  4.  
  5. Remove the coolant overflow tank by disconnecting the wiring and coolant hose, removing the 2 mounting nuts, and then pull it off the mounting studs.
  6.  
  7. Disconnect the accelerator and cruise control cables.
  8.  
  9. Disconnect the fuel hoses running between the injection pump and the filter system (supply and return).
  10.  
  11. Disconnect the vacuum hoses connecting to the rear of the engine block.
  12.  
  13. Disconnect the plug near the rear of the cylinder head and disconnect the ground wire nearby.
  14.  
  15. Disconnect the water hoses for the heater.
  16.  
  17. Disconnect the hoses going into the air cleaner. Unscrew the wingnuts, release the clamps, and remove the air cleaner.
  18.  
  19. Place a suitable container underneath the oil cooler and then disconnect both oil lines. Disconnect the manifold pressure line going to the turbo wastegate.
  20.  
  21. Disconnect the multi-prong plug on the control unit in the glovebox. Disconnect the engine wiring harness and feed it into the engine compartment.
  22.  
  23. Disconnect the engine ground strap.
  24.  
  25. Attach a lifting sling to the engine lifting hooks. Apply tension enough to support the engine.
  26.  
  27. Pull the center-bolts out of both engine mounts and remove the engine.
  28.  

To install:
  1. Guide the engine into the engine compartment, carefully. The engine mount has a guidepin that must fit into a corresponding bore in the front axle to locate the engine properly for installing of the mount through-bolts. Tighten the engine mounting bolts to 32 ft. lbs. (44 Nm).
  2.  
  3. Connect the electrical leads to the control unit and the ground strap to the body.
  4.  
  5. Connect the oil cooler lines and connect the pressure line to the turbocharger. Install the air cleaner and connect all hoses to the air cleaner assembly.
  6.  
  7. Reconnect the water hoses to the heater. Connect the vacuum lines to the rear of the engine block. Connect the fuel lines between the injection pump and the filler system.
  8.  
  9. Connect the accelerator and cruise control cables. Connect all the plugs and wiring at the relay box and the timed heater unit.
  10.  
  11. Install the radiator and all hoses. Reattach the air conditioning compressor and the power steering pump.
  12.  
  13. Install the transmission as outlined in Drive Train . Install the hood support struts.
  14.  
  15. Top off all of the fluids. Connect the battery cables. Run the engine and check for proper timing and idle.
  16.  

528i and 530i Models

The transmission must be separated from the block prior to engine removal.

  1. Raise and support the vehicle on jackstands.
  2.  
  3. Remove the transmission as outlined in Drive Train .
  4.  
  5. Disconnect the exhaust pipe at the exhaust manifold.
  6.  
  7. Remove the power steering pump and place it out of the way along the inner fender panel using a piece of wire.
  8.  
  9. Lower the vehicle and scribe the hood hinge location. Remove the hood and place aside.
  10.  
  11. Remove the air cleaner with the duct work attached. Disconnect and remove the air volume control.
  12.  
  13. Disconnect and remove the battery.
  14.  
  15. Disconnect all electrical wires and connectors. Mark the wires and connector for installation.
  16.  
  17. Disconnect all vacuum hoses, marking them for installation.
  18.  
  19. Drain the cooling system, then disconnect the hoses and remove the radiator.
  20.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the accelerator linkage.
  2.  
  3. Install a lifting sling on the engine and remove any slack.
  4.  
  5. Remove the left and right engine mount retainer nuts and washers.
  6.  
  7. Carefully lift the engine from the engine compartment.
  8.  

To install:
  1. Lower the engine into the engine compartment. When the engine is positioned, the guide pin must fit in the bore of the axle carrier. Tighten the mounting bolts on the front axle carrier (small bolt) to 18-20 ft. lbs. (23;26 Nm), the larger bolt to 31-35 ft. lbs. (40-45 Nm). The mount-to-bracket bolts are tightened to 31-35 ft. lbs. (40-45 Nm).
  2.  
  3. Connect the fuel lines, using new hose clamps where needed to connect the fuel lines to the fuel filter. Connect all of the multi-prong plugs and all vacuum hoses.
  4.  
  5. Install the air conditioning compressor and power steering pump. Properly route the accessory drive belt. Adjust the belt tension.
  6.  
  7. Install the radiator and connect the hoses.
  8.  
  9. Install the transmission as outlined in Drive Train .
  10.  
  11. Install the hood support and lower the hood.
  12.  
  13. Make sure all fluid levels are correct before starting the engine. Bleed air from the cooling system.
  14.  

528e Models

The transmission must be separated from the block prior to engine removal.

  1. Remove the transmission as detailed in Drive Train .
  2.  
  3. Disconnect the exhaust pipe from the exhaust manifold.
  4.  
  5. With the hoses attached, remove the power steering pump and position it out of the way using a piece of wire.
  6.  
  7. Unscrew the drain plug on the engine block, remove the upper and lower radiator hoses and drain the cooling system. After draining, remove the radiator.
  8.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. With the refrigerant hoses still connected, remove the air conditioning compressor and position it out of the way using a piece of wire.
  2.  
  3. Disconnect the gas pressure hood springs, then scribe around the hinges and then remove the hood.
  4.  
  5. Disconnect the battery cables (negative first) and remove the battery.
  6.  
  7. Disconnect the accelerator and cruise control cables. Disconnect all hoses from the throttle housing (make sure you tag them all).
  8.  
  9. Disconnect the air duct.
  10.  
  11. Remove the air filter housing along with the air flow sensor.
  12.  
  13. Tag and disconnect all remaining lines, hoses and wires which may interfere with engine removal.
  14.  
  15. Tag and disconnect all plugs and wires attached to the control unit in the glove box. Unscrew the straps on the firewall and pull the wire harness through to the engine compartment.
  16.  
  17. Disconnect the engine ground strap.
  18.  
  19. Loosen both engine mounts.
  20.  
  21. Attach an engine lifting hoist to the front and rear of the engine, remove the engine mount bolts and then lift out the engine.
  22.  

To install:
  1. Lower the engine into the engine compartment. When the engine is positioned, the guide pin must fit in the bore of the axle carrier. Tighten the mounting bolts on the front axle carrier (small bolt) to 18-20 ft. lbs. (23-26 Nm), the larger bolt to 31-35 ft. lbs. (40-45 Nm).
  2.  
  3. Connect all of the electrical wiring and all vacuum hoses.
  4.  
  5. Connect the accelerator cable and cruise control cable to the throttle body and adjust.
  6.  
  7. Install the air cleaner and reconnect all electrical plugs.
  8.  
  9. Reconnect the wiring to the main control unit in the interior of the vehicle.
  10.  
  11. Install the air conditioning compressor and power steering pump. Properly route the accessory drive belt. Adjust the belt tension.
  12.  
  13. Install the radiator and connect the hoses.
  14.  
  15. Install the transmission as described in Drive Train .
  16.  
  17. Install the hood support and lower the hood.
  18.  
  19. Make sure all fluid levels are correct before starting the engine. Bleed the air from the cooling system.
  20.  

630CSi Models

The transmission must be separated from the block prior to engine removal.

  1. Raise and support the vehicle on jackstands.
  2.  
  3. Remove the transmission as outlined in Drive Train .
  4.  
  5. Disconnect the exhaust pipe at the manifold.
  6.  
  7. Remove the power steering pump and place it out of the way using a piece of wire. Leave the hoses attached.
  8.  
  9. If equipped with air conditioning, remove the compressor and place it aside securing with wire. Do not remove the hoses.
  10.  
  11. Scribe the hood hinge locations and remove the hood.
  12.  
  13. Drain the cooling system, disconnect the hoses and remove the radiator.
  14.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the air cleaner housing at the wheel housing.
  2.  
  3. Remove the electrical wires and connectors from the engine components. Tag the wires and connectors.
  4.  

The fuel injection control box is located either above the glove box or behind the right side kick panel. Remove the plug and thread the wire and connector through the hole in the firewall into the engine compartment.

  1. Tag and disconnect all plugs and wires attached to the control unit in the glove box. Unscrew the straps on the firewall and pull the wire harness through to the engine compartment.
  2.  
  3. Disconnect the engine ground strap.
  4.  
  5. Loosen both engine mounts.
  6.  
  7. Attach an engine lifting hoist to the front and rear of the engine and take up any slack.
  8.  
  9. Remove the engine mount bolts.
  10.  
  11. Lift out the engine.
  12.  

To install:
  1. Lower the engine into the engine compartment. When the engine is positioned, the guide pin must fit in the bore of the axle carrier. Tighten the mounting bolts on the front axle carrier (small bolt) to 18-20 ft. lbs. (23;26 Nm), the larger bolt to 31-35 ft. lbs. (40-45 Nm).
  2.  
  3. Connect all of the electrical wiring and all vacuum hoses.
  4.  
  5. Connect the accelerator cable and cruise control cable to the throttle body and adjust.
  6.  
  7. Install the air cleaner and reconnect all electrical plugs.
  8.  
  9. Reconnect the wiring to the main control unit.
  10.  
  11. Install the air conditioning compressor and power steering pump. Properly route the accessory drive belt. Adjust the belt tension.
  12.  
  13. Install the radiator and connect the hoses.
  14.  
  15. Install the transmission as outlined in Drive Train .
  16.  
  17. Install the hood support and lower the hood.
  18.  
  19. Make sure all fluid levels are correct before starting the engine. Bleed the air from the cooling system.
  20.  

533i, 535i, 633CSi and 635CSi Models

The transmission must be separated from the block prior to engine removal.

  1. Disconnect the battery cable from the battery, negative side first. Open the hood to the widest position possible and secure in place.
  2.  


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

  1. Remove the splash shield from under the vehicle.
  2.  
  3. Drain the coolant and remove the fan and radiator.
  4.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the transmission as outlined in Drive Train .
  2.  
  3. Disconnect the throttle cable and the cruise control cable. Disconnect the cable brackets from the intake manifold.
  4.  
  5. Loosen and remove the connections to the air cleaner assembly. Remove the air cleaner assembly and airflow meter from the engine.
  6.  
  7. Disconnect the coolant hoses from the engine.
  8.  
  9. Mark the feed and return fuel line connections. Remove the fuel lines, catching any excess fuel with a rag or suitable container placed underneath.
  10.  
  11. Disconnect the idle speed control.
  12.  
  13. 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.
  20.  
  21. Disconnect the starter and the alternator wiring. Disconnect the plug located behind the alternator.
  22.  
  23. Disconnect the engine harness and place off to the side.
  24.  
  25. Disconnect the ground strap.
  26.  
  27. Connect an engine lifting sling to the engine.
  28.  
  29. Disconnect the left engine mount from above and the right side mount from under the vehicle.
  30.  
  31. Lift the engine out of the car.
  32.  

To install:
  1. Install the engine and tighten the motor mounts to 32 ft. lbs. (45 Nm).
  2.  
  3. Install the ground strap.
  4.  
  5. Install the engine wiring harness and connect the sensors and hoses.
  6.  
  7. Connect the alternator and starter. Connect the plug located behind the alternator.
  8.  
  9. Install the oil cooler lines, if equipped. Tighten to 22-29 ft. lbs. (30-40 Nm).
  10.  
  11. Connect the ignition coil.
  12.  
  13. Connect the coolant lines and pipes.
  14.  
  15. Connect the vacuum line going into the passenger compartment.
  16.  
  17. Install the idle speed control and the brake booster vacuum line. Connect the radiator hoses and the fuel lines to the previously marked locations.
  18.  
  19. Install the air cleaner and the air flow meter.
  20.  
  21. Connect the air ducts and the electrical connections.
  22.  
  23. Install the throttle cables and the bracket.
  24.  
  25. Install the air conditioner compressor and the power steering pump. Tension the belts.
  26.  
  27. Install the radiator and connect the hoses.
  28.  
  29. Install the transmission.
  30.  
  31. Install the hood support.
  32.  
  33. Make sure all fluid levels are correct before starting the engine. Bleed air from the cooling system.
  34.  

M5 and M6 Models

The transmission must be separated from the block prior to engine removal.

  1. Disconnect the battery terminals, negative side first, and remove the battery, if mounted in engine compartment. Unscrew and remove the battery tray.
  2.  
  3. Remove the transmission as outlined in Drive Train .
  4.  
  5. Loosen the clamp on the cooling duct to the alternator and remove the duct.
  6.  
  7. 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.
  8.  
  9. Hold the fan pulley while unscrewing the fan nut from the shaft. The shaft uses left hand threads, turn the nut clockwise to unscrew.
  10.  
  11. Drain the coolant from the engine block and radiator. The drain plug on the block is located between the exhaust manifolds. Disconnect the coolant hoses from the radiator and remove the coolant level switch plug.
  12.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. On automatic transmission equipped vehicles, remove the cooler lines at the radiator and plug.
  2.  
  3. 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.
  4.  
  5. Pull the plug off of the air conditioner temperature switch.
  6.  
  7. 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.
  8.  
  9. Disconnect the heater hoses from the heater valve and the heater.
  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. Unscrew the bolt holding the ground strap on the front lifting eye. Replace the bolt before lifting the engine out of the vehicle.
  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 throttle valve switch plug. Unclip the idle speed control valve mounted on the manifold. Disconnect the fuel hoses from the pipes.
  20.  
  21. 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 and plug the hole.
  22.  
  23. Remove the electric leads from the alternator and the starter. Unscrew the electrical lead tray and place the engine wiring harness to the side.
  24.  
  25. Loosen the drive belt for the power steering pump and the air conditioner compressor by turning their respective tensioners. Release the tension on the belt and allow the belt to be removed.
  26.  
  27. Unbolt the power steering pump and secure to the side with a piece of wire. Unbolt the air conditioner compressor and place to the side with apiece of wire.
  28.  
  29. Attach a lifting tool to the engine hooks taking up any excess slack. Unscrew the engine mounts and ground strap.
  30.  
  31. 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 oxygen sensor.
  6.  
  7. 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.
  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. 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.
  24.  
  25. 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.
  26.  
  27. Install the fan and tighten the nut to 29 ft. lbs. (40 Nm). Replace the radiator cowling.
  28.  
  29. Replace the air cleaner assembly and connect the electrical plug.
  30.  
  31. Install the transmission as outlined in Drive Train .
  32.  
  33. Fill and bleed the cooling system.
  34.  
  35. Install the battery tray and battery. Check all fluids before starting engine.
  36.  

1982 733i Models

The transmission must be separated from the block prior to engine removal.

  1. Raise and support the vehicle on jackstands.
  2.  
  3. Remove the transmission as outlined in Drive Train .
  4.  
  5. Disconnect the exhaust pipe at the exhaust manifold or thermal reactor.
  6.  
  7. Remove the clutch housing from the engine.
  8.  
  9. Remove the power steering pump and place it out of the way using a piece of wire to secure it to the vehicle body. Do not disconnect the hoses.
  10.  
  11. If equipped with air conditioning, remove the compressor and place it out of the way using a piece of wire. Do not disconnect the hoses.
  12.  
  13. Remove the damper bracket from the crankcase and lower the vehicle.
  14.  
  15. Scribe the hood hinge locations and remove the hood.
  16.  
  17. Drain the cooling system, disconnect the hoses and remove the radiator.
  18.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the windshield washer reservoir and the air filter housing located on the inner fender panel.
  2.  
  3. Remove the electrical wiring from the engine components. Tag all wires.
  4.  
  5. Disconnect and remove the battery.
  6.  
  7. Remove and tag all vacuum hoses.
  8.  

Some vacuum hoses are color coded.

  1. Disconnect the throttle linkage.
  2.  
  3. Remove the right kick panel from the passenger compartment. Remove the fuel injection control unit wire connector and thread the connector and wire through the hole in the firewall.
  4.  
  5. Attach a lifting sling to the engine.
  6.  
  7. Remove the left and right engine mount retaining nuts and washers.
  8.  
  9. Lift the engine from the engine compartment.
  10.  

To install:
  1. Lower the engine into the engine compartment. When the engine is positioned, the guide pin must fit in the bore of the axle carrier. Tighten the mounting bolts on the front axle carrier (small bolt) to 18-20 ft. lbs. (23;26 Nm), the larger bolt to 31-35 ft. lbs. (40-45 Nm).
  2.  
  3. Connect all of the electrical wiring and all vacuum hoses.
  4.  
  5. Connect the accelerator cable and cruise control cable to the throttle body and adjust.
  6.  
  7. Install the air cleaner and reconnect all electrical plugs.
  8.  
  9. Reconnect the wiring to the main control unit.
  10.  
  11. Install the air conditioning compressor and power steering pump. Properly route the accessory drive belt. Adjust the belt tension.
  12.  
  13. Install the radiator and connect the hoses.
  14.  
  15. Install the transmission as described in Drive Train .
  16.  
  17. Install the hood support and lower the hood.
  18.  
  19. Make sure all fluid levels are correct before starting the engine. Bleed the air from the cooling system.
  20.  

733i and 735i
1983-86 MODELS

The transmission must be separated from the block prior to engine removal.

  1. Disconnect the cables from the battery, negative side first.
  2.  
  3. Open the hood to the widest position possible and secure in place.
  4.  


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

  1. Remove the splash shield from under the car.
  2.  
  3. Drain the coolant and remove the radiator
  4.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the transmission as outlined in Drive Train .
  2.  
  3. Remove the nut holding the transmission oil cooler lines to the engine oil pan.
  4.  
  5. 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 without any tension on the hoses.
  6.  
  7. Disconnect the hoses from the coolant expansion tank. Remove the screws on the side of the expansion tank and the expansion tank from the engine compartment.
  8.  
  9. Disconnect the heater hoses from the heater control valve and the heater inlet pipe.
  10.  
  11. Pull off the connections to the ignition coil.
  12.  
  13. Remove the air cleaner assembly.
  14.  
  15. Disconnect and remove the idle speed control from the intake duct.
  16.  
  17. Disconnect the harness to the airflow meter. Disconnect the ducting to the air flow meter and remove along with the crankcase breather vacuum line.
  18.  
  19. Disconnect the cruise control cable and the throttle cable at the throttle. Remove the cable mounting bracket.
  20.  
  21. Disconnect the leads to the starter. Disconnect the 2 electrical connectors in the starter area.
  22.  
  23. Disconnect the oil level sender leads and the alternator connections. Remove the air duct to the alternator.
  24.  
  25. Disconnect the tank venting valve and the hose to the carbon canister.
  26.  
  27. Mark the feed and return fuel lines. Disconnect the lines and catch any spilled fuel with a rag or suitable container placed underneath.
  28.  
  29. Disconnect the vacuum line from the brake booster and plug the opening.
  30.  
  31. Disconnect the ground strap and make a check for any remaining lines or electrical leads still attached.
  32.  
  33. Attach a lifting sling to the engine and take up any slack.
  34.  
  35. Remove the engine mount nuts and bolts and lift the engine from the engine bay.
  36.  

To install:
  1. Install the engine into the engine compartment. Tighten the engine mounts to 32 ft. lbs. (45 Nm). Connect the ground strap.
  2.  
  3. Connect the brake booster vacuum line.
  4.  
  5. Connect the fuel lines to their proper locations as previously marked.
  6.  
  7. Connect the tank venting valve and the carbon canister line.
  8.  
  9. Attach the alternator leads and the cooling duct.
  10.  
  11. Connect the starter leads and the electrical connector in the starter area.
  12.  
  13. Connect the oil level sender leads.
  14.  
  15. Connect the throttle cable and the cruise control cable and bracket.
  16.  
  17. Install the airflow sensor and the crankcase breather line.
  18.  
  19. Install the idle speed control to the air intake duct. Install the air cleaner assembly.
  20.  
  21. Connect the heater lines to the heater control valve and the heater inlet pipe. Install the coolant expansion tank and connect the lines.
  22.  
  23. Install the air conditioner compressor and power steering pump. Adjust the belt tensions.
  24.  
  25. Connect the transmission oil cooling lines to the bracket on the engine oil pan.
  26.  
  27. Install the transmission as outlined in Drive Train .
  28.  
  29. Install the radiator. Fill the cooling system.
  30.  
  31. Check all other engine fluids levels and adjust if needed.
  32.  
  33. Install the splash shield.
  34.  
  35. Connect the battery cables, positive, then negative.
  36.  
  37. Run the engine and check for leaks. Bleed the cooling system.
  38.  

1987-88 735i MODELS
  1. Disconnect first the negative battery cable and then the positive.
  2.  
  3. Remove the transmission as described in Drive Train .
  4.  
  5. Scribe hinge locations and remove the hood, or remove the support struts and prop it securely.
  6.  


CAUTION
In lifting up the hood, the hood must be propped in a secure manner! If it falls during work serious injury could result.

  1. Remove the splash guard from underneath the engine.
  2.  
  3. Remove the drain plugs in the radiator and engine block and drain the engine coolant.
  4.  


CAUTION
When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Loosen the power steering pump bolts from underneath. Turn the adjusting pinion to loosen the belt and remove. Then, remove the mounting bolts and remove the power steering pump without disconnecting the hoses. Support the pump out of the way with wire.
  2.  
  3. Remove the air conditioner compressor. This unit does not have the belt adjusting pinion. It is necessary, only to loosen all the bolts and push the compressor toward the engine to remove the belt. Use wire to secure the compressor to the vehicle body.
  4.  
  5. Loosen the air intake hose clamp and disconnect the hose. Remove the mounting nut and then remove the air cleaner assembly.
  6.  
  7. The unit on the opposite side of the intake hose from the air cleaner contains the idle speed control valve, which must be removed. Loosen the hose clamps and pull off the hoses. Disconnect the electrical connector. Remove the mounting nut and then pull the idle speed control out of the air intake hose.
  8.  
  9. Pull off the 3 retainers for the airflow sensor, and then pull the unit off its mounting, disconnecting the vacuum hose from the PCV system at the same time.
  10.  
  11. Working on the coolant expansion tank, unfasten the electrical connector. Remove the nuts on both sides. Loosen the clamps and disconnect all 3 hoses and remove the tank.
  12.  
  13. Disconnect the heater hoses at both the control valve and at the heater core.
  14.  
  15. Disconnect the throttle and cruise control cables at the throttle lever. Unbolt the cable housing retainer and remove the housing and cables.
  16.  
  17. Pull off the low amperage starter connectors and disconnect the high amperage connector coming from the battery.
  18.  
  19. Unfasten the connecting plug for the oxygen sensor.
  20.  
  21. Loosen the clamps and then disconnect the fuel supply and return pipes, draining fuel into a metal container for safe disposal.
  22.  
  23. Disconnect the fuel pipe at the injector supply manifold.
  24.  
  25. Unfasten the electrical connector at the throttle body. Lift off the protective caps and remove the attaching nuts for the protective cover for the wiring harness for the injectors and remove.
  26.  
  27. Disconnect the ground strap at the block.
  28.  
  29. Remove the upper engine mount nuts from both sides of the engine.
  30.  
  31. Attach a lifting sling to the engine and support the assembly with a crane or other equivalent lifting device.
  32.  
  33. Disconnect the ground lead.
  34.  
  35. Carefully lift the engine out of the compartment, tilting the front of the engine upward for clearance.
  36.  

Then, carefully lift the engine out of the compartment, avoiding contact between it and the components remaining in the car.

To install:
  1. Keep these points in mind during installation:
    1. Tighten the engine mounting bolts to 32 ft. lbs. (42 Nm).
    2.  
    3. Adjust the belt tension for the air conditioning compressor and power steering pump drive belts to give 0.5-0.75 inches (13-19 Nm) deflection.
    4.  
    5. Tighten the oil cooler line flare nuts to 25 ft. lbs. (32 Nm).
    6.  
    7. When reconnecting the intake manifold to the throttle necks, inspect and, if necessary, replace the O-rings. Tighten the mounting nuts to 78 in. lbs. (9 Nm).
    8.  

  2.  
  3. To install, reverse the procedures used for removal.
  4.  
  5. Lower the engine into the engine compartment. When the engine is positioned, the guide pin must fit in the bore of the axle carrier. Tighten the mounting bolts on the front axle carrier (small bolt) to 18-20 ft. lbs. (23;26 Nm), the larger bolt to 31-35 ft. lbs. (40-45 Nm).
  6.  
  7. Connect the fuel lines, using new hose clamps to connect the fuel lines to the fuel filter.
  8.  
  9. Connect all of the multi-prong plugs and all vacuum hoses.
  10.  
  11. Connect the accelerator cable and cruise control cable to the throttle body and adjust.
  12.  
  13. Install the coolant recovery tank, using a new hose clamp on the coolant expansion tank.
  14.  
  15. Install the air cleaner and reconnect all electrical plugs. Connect and install the relays in the relay box.
  16.  
  17. Reconnect the wiring to the main control unit and install the idle control unit.
  18.  
  19. Install the air conditioning compressor and power steering pump. Properly route the accessory drive belt. Adjust the belt tension.
  20.  
  21. Install the radiator and connect the hoses.
  22.  
  23. Install the transmission as described in Drive Train .
  24.  
  25. Install the hood support and lower the hood.
  26.  
  27. Make sure all fluid levels are correct before starting the engine. Bleed air from the cooling system.
  28.  

 
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