7
.
Unbolt
timing
chain
casefrom
frontof
engine
.
See
Fig
.
13
.
9
.
Installation
is
reverse
of
removal
.
Fig
.
13
.
Timing
chain
case
mounting
bolts
(arrows)
on
M44
engine
.
8
.
Remove
cover
from
oil
pump
on
rear
of
timing
chain
case
.
See
Fig
.
14
.
Inspect
oil
pump
gears
and
oil
pump
cavity
in
timing
chain
case
for
wear
andlor
scoring
.
Fig
.
14
.
Oil
pump
cover
mounting
bolts
(arrows)
on
M44
engine
.
LUBRICATION
SYSTEM
119-
9
"
Replace
al¡
gaskets
and
O-rings
.
"
Install
a
new
rubber
sea¡
(profile
gasket)
between
top
of
timing
chain
case
and
cylinder
head
.
"
Be
sure
to
thoroughly
clean
sealing
surfaces
.
-Use
3-Bond
1209
orequivalent
sealant
on
both
sides
of
sea¡
before
installing
.
10
.
Protect
profile
gasket
using
thin
sheet
metal
(BMW
special
tool
no
.
11
2
330)
when
installing
timing
chain
case
.
See
Fig
.
15
.
"
Applya
thin
coating
of
grease
to
both
sides
of
sheet
metal
tool
and
to
top
surface
of
profile
gasket
.
"
Placesheet
metal
between
gasket
and
cylinder
head
and
carefully
slíde
upper
chain
cover
into
position
.
"
Tighten
al¡
mounting
bolts
and
then
carefully
withdraw
sheet
metal
.
Install
timing
chain
as
described
in
117
Camshaft
Timing
Chain
.
Fig
.
15
.
Use
thin
sheetmetal
(arrow)
toprotect
profile
gasket
during
installation
of
timing
chain
case
.
Carefully
withdraw
sheetmetal
after
tightening
fasteners
.
Tightening
Torques
"
Timing
chain
case
to
engine
block
M6
..
.
...
...
.
..
.............
.
.10
Nm
(7
.5
ft-Ib)
M8
........
.
..
..
..............
22
Nm
(16
ft-Ib)
"
Thermostathousing
to
upper
timing
chain
cover(M6)
............
10
Nm
(89
in-lb)
"
OH
filter
cover
to
oil
filter
housing
(M8)
.
.
.........
25
Nm
(18
ft-lb)
"
Oil
pump
cover
to
timing
chain
case
(M6)
...
..
.......
10
Nm
(89
in-lb)
"
Oil
pan
to
engine
block
(M6
bolt)
8
.8
grade
.........
.
.
..
.........
10
Nm
(89
in-lb)
10
.9
grade
............
.
.......
12
Nm
(106
in-lb)
"
Alternator
to
alternator
bracket
.....
43
Nm
(32
ft-Ib)
OIL
PUMP
119-
1
0
LUBRICATION
SYSTEM
Oil
pump,
removing
and
installing
(6-cylinder
engine)
Oil
pressure
on
the
6-cylinder
engines
is
generated
by
a
gear-type
pump
bolted
to
the
bottom
of
the
engine
block
.
The
oil
pump
is
chain
driven
off
the
front
of
the
crankshaft
.
NOTE-
Oil
pump
removal
requires
raising
the
engine
(cars
built
up
to
9-92)
or
lowering
the
front
suspension
crossmem-
ber
(cars
built
from
9-92)
to
remove
the
oil
pan
.
1.
Drain
oil
as
described
in
020
Maintenance
Program
.
2
.
Remove
oil
pan
as
described
earlier
.
3
.
Remove
oil
pump
sprocket
mounting
nut
(left-hand
thread)
.
See
Fig
.
16
.
Lift
sprocket
off
together
with
drive
chain
.
Fig
.
16
.
Oil
pump
sprocket
mounting
nut
(left-hand
thread)
on
6-cylin-
der
engine
(arrow)
.
4
.
Remove
mounting
bolts
from
oil
pump
and
oil
pump
pickup
tube
.
Withdraw
pump
.
NOTE-
Note
any
spacers
between
pump
and
engine
block
.
See
Fig
.
17
.
"
Note
position
of
locating
dowels
.
OIL
PUMP
811186
0011952
Fig
.
17
.
Oil
pump
mounting
points
(1)
and
pickup
tube
mountíng
points
(2)
.
5
.
Remove
coverfrom
oil
pump
and
check
for
wear
or
scoring
.
Spin
oil
pump
shaft
and
check
that
gears
turn
smoothly
.
Replace
pump
if
gears
spinwith
difficulty
or
any
wear
is
present
.
6
.
Installation
is
reverse
of
removal,
noting
the
following
:
"
Align
sprocket
splines
to
oil
pump
shaft
splines
before
tightening
sprocket
nut
.
Tightening
Torques
"
Oil
pump
to
engine
block
(M8)
......
22
Nm
(16
ft-Ib)
"
Oil
pan
to
engine
block
(M6
bolt)
8
.8
grade
..
...
.
...
...
.
.........
10
Nm
(89
in-lb)
10
.9
grade
.
...
.
..
....
.
........
12
Nm
(106
in-lb)
"
Oil
pump
sprocket
to
oil
pump
shaft
(M1
0x1
left-hand
thread)
..........
25
Nm
(18
ft-Ib)
121-
8
BATTERY,
STARTER,
ALTERNATOR
1f
the
solenoid
audibly
cliicks
but
the
motor
does
not
turn,
Starter,
removing
and
installing
switch
on
the
lights
andtum
the
key
to
the
start
position
.
lf
the
(6-cylinder
engine
with
lights
go
out
while
attempting
to
start,
the
battery
cable
may
be
manual
transmission)
loose
or
the
starter
may
have
a
short
circuit
.
If
the
lights
stay
on,the
solenoid
is
most
likely
atfault
.
The
starter
on
a
6-cylinder
car
with
manual
transmission
is
Starter,
removing
and
installing
(4-cylinder
engine)
1
.
Disconnect
negative
(-)
battery
cable
.
1
.
Disconnect
negative
(-)
cable
from
battery
.
CAUTION-
Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
viii
.
2
.
Remove
guide
tube
for
oil
dipstick
.
3
.
Raise
vehicle
.
WARNING
-
Make
sure
the
car
ís
stable
and
wefl
supported
at
all
times
.
Use
a
professional
automotive
lift
or
jack
stands
designed
forthe
purpose
.
A
floor
jack
is
not
adequate
support
.
4
.
Disconnect
wiring
from
starter
.
5
.
Remove
top
and
bottom
starter
bolts
.
Bottom
bolt
must
be
removed
from
below
car
.
Remove
starter
support
bracket,
if
applicable
.
removed
from
below
.
2
.
Raise
vehicle
.
3
.
Remove
reinforcing
cross
bracefromunder
transmís-
sion,
if
applicable
.
4
.
Remove
cover
from
fuel
filter
and
fuel
lines
on
left
side
underneath
car,
if
applicable
.
Detach
fuel
lines
and
har-
ness
connectors
from
retainingbrackets,
as
necessary
5
.
Disconnect
wiring
from
starter
.
6
.
Loosen
andremove
bolts
and
nuts
fastening
starter
to
transmission
bell
housing
and/or
engine
block
.
Remove
starter
supportbracket
.
7
.
Remove
starter
from
below
.
8
.
Check
starter
pinion
gear
and
flywheel
teeth
for
dam-
age
.
9
.
Installation
is
reverse
of
removal
.
6
.
Pull
starter
downward
and
turn
until
solenoid
is
at
top,
Tightening
Torques
then
remove
from
car
.
"
Re¡
nforcing
cross
brace
to
chassis
(M10)
..
...............
42
Nm
(31
ft-Ib)
7
.
>Check
starter
pinion
gear
and
flywheel
teeth
for
dam-
"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-Ib)
age
.
"
Support
bracket
to
starter
(M5
nut)
...
5
Nm
(44
in-lb)
"
Support
bracket
8
.
Installation
is
reverse
of
removal
.
to
engine
block
(M10
bolt)
.........
47
Nm
(35
ft-Ib)
"
Wire
to
terminal
50
(M6
nut)
.........
6
Nm
(53
ín-Ib)
"
Wire
to
terminal
30
(M8
nut)
.........
12
Nm
(9
ft-lb)
Tightening
Torques
"
Starter
to
engine
block
(M10
bolt)
...
50
Nm
(37
ft-lb)
Wire
to
terminal
50
(M6
nut)
........
6
Nm
(53
in-lb)
"
Wire
toterminal
30
(M8
nut)
...
,
..:.
12
Nm
(9
ft-Ib)
STARTER
SERVICE
Starter,
removing
and
installing
(6-cylinder
engine
with
automatic
transmission)
The
starter
on
a
6-cylinder
car
with
automatic
transmission
ís
removed
from
above
.
It
is
necessary
to
remove
the
íntake
manifold
and
disconnect
a
number
of
electrical
harness
con-
nectors
.
1
.
Disconnect
negative
(-)
battery
cable
.
2
.
Remove
air
plenum
from
rear
of
engine
compartment
.
See640
Heating
and
Air
Conditioning
.
3
.
Remove
top
enginecovers
.
See
Fig
.
9
.
Fig
.
9
.
Remove
top
engine
cover
by
prying
out
plugs
and
removing
nuts
(A)
.
Make
sure
rubber
insulators
(B)
on
either
sideof
large
cover
do
not
fall
off
during
cover
removal
.
4
.
Remove
ignition
coil
harness
connectors
.
Remove
ground
connection
at
front
of
cylinder
head
.
5
.
Remove
two
retaining
bolts
and
lift
off
fuel
injector
har-
ness
connector
strip
.
Carefully
fold
away
all
harnesses
toward
right
side
of
engine
compartment
and
place
at
base
of
windshield
.
See
Fig
.
10
.
6
.
Remove
intake
manifold
.
See
113
Cylinder
Head
Re-
moval
and
Installation
.
7
.
Disconnect
wiring
from
starter
.
BATTERY,
STARTER,
ALTERNATOR
121-
9
Fig
.
10
.
Fuel
injection
harness
(A)
and
ignition
coíl
harness
connectors
(B)
being
lifted
off
engine
to
be
placed
at
base
ofwindshield
.
M50
engine
shown
.
Other
6-cylinder
engines
are
similar
.
8
.
Loosen
and
remove
bolts
and
nuts
fastening
starter
to
transmission
bell
housing
and/or
engine
block
.
Remove
starter
support
bracket
.
Fig
.
11
.
Starter
wiring
terminals
and
support
bracket(arrow)
.
Intake
manifold
has
been
removed
.
STARTER
SERVICE
210-
4
CLUTCH
Clutch,
removing
1
.
Remove
transmission
fromengine
.
See230
Manual
Transmission
.
2
.
Remove
release
bearing
from
transmission
inputshaft
.
3
.
Remove
clutch
release
lever
by
sliding
it
out
from
under
spring
clip
.
See
Fig
.
5
.
Fig
.
5
.
Remove
clutch
release
lever
by
pulling
away
from
spring
clip
in
direction
of
arrow
.
4
.
Lock
flywheel
in
posítion
using
a
suitable
locking
tool
(BMW
Special
tool
no
.
11
2
170,or
equivalent)
.
See
Fig
.
6
.
Fig
.
6
.
Flywheel
locking
tool
(arrow)
installed
to
rear
of
cylinder
block
.
CLUTCH
MECHANICAL
0011581
0012008
5
.
Install
a
clutch
centering
tool
through
clutch
assembly
to
prevent
clutch
disc
from
falling
out
when
removing
pressure
plate
.
See
Fig
.
7
.
Fig
.
7
.
Clutch
centering
tool
(arrow)
shown
installed
through
clutch
disc
and
flywheel
.
6
.
Remove
six
bolts
from
perimeter
of
pressure
plate
.
Re-
move
pressure
plate
and
clutch
disc
.
See
Fig
.
8
.
Fig
.
8
.
Clutch
pressure
plate
mounting
bolts
(arrows)
.
0012009
6529
8
.
Disconnect
main
harness
connector
from
transmission
by
turning
its
bayonet
lock
ring
counterclockwise
.
Re-
move
wiring
harness
from
transmission
housing
.
See
Fig
.
8
.
Fig
.
8
.
Harness
connector
at
automatic
transmission
.
9
.
Where
applicable,
disconnect
harness
connector
from
speed
sensor
at
top
óf
transmission
.
10
.
Disconnect
transmission
cooler
line
clamps
from
en-
gine
.
Disconnect
lines
from
transmission
.
11
.
Support
transmission
with
transmission
jack
.
Remove
reinforcing
cross
brace
(if
applicable)
and
transmission
support
crossmember
.
NOTE-
Note
installation
positionof
support
crossmember
.
12
.
Remove
access
plug
in
cover
plate
on
right
side
of
en-
gine
block
and
remove
torqueconverter
bolts
.
Turn
crankshaft
to
access
boits
.
See
Fig
.
9
.
AUTOMATIC
TRANSMISSION
240-
5
Bellhousing
access
hole
Socket
wrench
Fig
.
9
.
Access
andremove
torque
converter
boits
through
hole
in
bellhousing
cover
.
0
A
fij
13
.
Remove
bellhousing-to-engine
mounting
bolts
.
See
Fig
.
10
.
Transmission-to-engine
Torx-head
mounting
bolts
.
Fig
.
10
.
0012592
TRANSMISSION
REMOVAL
AND
INSTALLATION
Fig
.
3
.
Power
steering
pump
and
pulley
mounting
bolts
.
6
.
Installation
is
reverse
of
removal,
noting
the
following
:
"
Make
sure
al¡
thread
bores,
bolts,
nuts,
fluid
couplings
and
mating
surfaces
are
clean,
and
that
inside
surface
of
multi-ribbed-belt
is
free
of
grease
and
dirt
.
"
Use
new
sealing
washers
when
reattaching
power
steering
pressure
lines
.
"
Make
sure
hoses
have
adequate
clearance
from
chas-
sis
.
Do
not
over-torque
banjo
bolts
.
"
Fill
and
bleed
power
steering
system
as
described
be-
low
.
Power
steering
system,
bleeding
and
filling
1
.
Wíth
engine
off,
fill
power
steering
fluid
reservoir
with
clean
fluid
.
Fill
levelto
MAX
mark
on
dipstick
.
STEERING
AND
WHEEL
ALIGNMENT
320-
3
STEERING
GEAR
A
cutaway
of
the
power-assisted
rack-and-pinion
power
steering
gear
is
shown
in
Fig
.
4
.
The
rack
is
designed
to
be
maintenance
free
.
Pinion
Fig
.
4
.
Cutaway
of
rack-and-pinion
steering
gear
.
Tightening
Torques
"
Hydraulic
hoses
to
power
steering
pump
?he
steering
gear
and
linkage
require
no
maintenance
oth-
M10
banjo
bolt
.........
..
.
...
...
.
12
Nm
(9
ft-Ib)
er
than
alignment
and
a
periodic
inspection
for
worn
compo
M14
banjo
bolt
..............
..
..
35
Nm
(26
ft-Ib)
nents
.
M16
banjo
bolt
..............
...
.
40
Nm
(30
ft-Ib)
"
Power
steering
pump
to
bracket
Steering
gear
rack,
removing
and
installing
(self-locking
nuts)
.............
..
.
22
Nm
(16
ft-Ib)
"
Power
steering
pump
bracket
to
engine
1
.
Empty
power
steering
fluid
reservoir
using
clean
sy-
block
or
oil
pan
(self-locking
nuts)
...
22
Nm
(16
ft-lb)
ringe
.
Do
not
reuse
fluid
.
2
.
Disconnect
negative
(-)
cable
from
battery
and
cover
terminal
with
insulating
material
.
CAUTION-
Prior
to
disconnectiog
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
viii
.
2
.
Start
engine
.
Slowly
turn
steering
wheelfrom
lock
to
lock
a
minimum
of
two
times
.
3
.
Carefully
remove
airbag
from
frontof
steering
wheel
.
See
721
Airbag
System
(SRS)
.
Store
airbag
unit
in
a
sale
3
.
Turn
engine
off
and
check
fluid
leve¡,
adding
fluid
if
nec-
place
.
essary
.
4
.
Make
sure
front
wheelsare
pointed
straight
ahead
.
5
.
Remove
outer
tie
rod
ball
joínt
nuts,
thenseparate
outer
tie
rod
ends
from
steering
arms
using
appropriate
press
tools
.
6
.
Disconnect
power
steering
hose
from
fluid
reservoir
.
STEERING
GEAR
Fig
.
36
.
6-cylinder
engine
belt
diagram
:
To
remove
A/C
belt,
lever
ten-
sioner
(A)
in
clockwise
direction
using
long-handled
wrench
or
breaker-bar
.
6
.
Disconnect
electrical
harness
connector
from
com-
pressor
.
7
.
Remove
A/C
pressure
hose
and
suction
hose
flange
10
.
Before
recharging,
evacuate
system
for
at
least
30
min
.
bolts
from
compressor
.
Plug
hoses
immediately
See
Recharge
system
following
equipment
manufacturer's
Fig
.
37
.
instructions
.
See
Table
d
.
A/C
System
Refrigerant
Capacities
.
0011879
Fig
.
37
.
A/
C
compressor
pressure
hose
(A)
and
suction
hose
(B)
.
(6-
cylinder
engine
shown
.
4-cylinder
engine
is
similar
.)
HEATING
AND
AIR
CONDITIONING
640-
1
3
Fig
.
38
.
A/
C
compressor
mounting
boits
(arrows)
.
9
.
Installation
is
reverseof
removal
.
CAUTION
-
"
Always
replaceO-rings
when
reconnecting
re-
frigerantfines
.
"
When
installlng
a
new
compressor
always
re-
place
receiverldrier
unit
.
Tightening
Torques
"
A/C
compressor
to
engine
block
....
22
Nm
(17
ft-Ib)
"
A/C
line
flange
to
A/C
compressor
5/8
in
.
fine
.
......
.....
....
.
.....
20
Nm
(15
ft-Ib)
3/4
in
.
fine
.......
.....
..........
39
Nm
(29
ft-Ib)
7/8
in
.
fine
...
....
.....
..........
42
Nm
(31
ft-Ib)
11/16
in
.
fine
.....
..
..
..
...
.
.....
48
Nm
(35
ft-Ib)
A/C
Compressor
Clutch
The
compressor
clutch
can
be
replaced
without
disturbing
thesealed
refrigerant
system,
although
clearances
in
the
six-
cylinder
cars
may
be
very
tight
.
Detach
the
compressor
from
the
compressor
bracket
togain
extra
clearance
.
8
.
Remove
compressor
mounting
boits
.
See
Fig
.
38
.
Re-
Typical
A/C
compressor
and
clutch
is
shown
in
Fig
.
39
.
move
compressor
by
pulling
downward
from
under-
neath
car
.
Remove
driveplate
and
pulley
to
access
clutch
magnetic
winding
.
See
Fig
.
40
.
AIR
CONDITIONING