1997 BMW 328i Cylinder 4

camshaft
secondary
drive,
causing
thecamshaft
to
"advance"

12
.5°
.
The
helical
gears
are
cut
so
that
forward
motion
of
the

gear
cup
is
transiated
into
rotational
motion
of
the
camshaft
.

See
117
Camshaft
Timing
Chain
for
testing
and
repair
infor-
mation
on
the
VANOS
system
.

DISA
(Dual
Resonance
Intake
System)

DISA,usedon
4-cylinder
engines,
is
a
dual
intake
runner

system
that
effectively
provides
the
advantages
of
both
short

and
long
intake
runners
within
the
same
engine
.
For
best
per-

formance,
long
intake
runners
aremost
beneficial
atlow-
and
mid-engine
speeds
(below
4,200
rpm),
and
short
intake
run-
ners
enhance
torque
at
high
engine
speeds
(above4,200
rpm)
.

NOTE-

The
term
DISA
comes
from
the
German
words
Differ-
enzierte
Sauganlage,
and
can
roughty
be
transiated
as
a
differing
intake
manifold
configuration
.

The
DISA
solenoid
valve
is
controlled
by
the
DME
control

module,
using
engine
speed
as
the
primary
input
.
The
main

components
of
the
system
are
the
modified
twin-section
in-

takemanifoldwith
change-over
valve,
the
twin-barrel
throttle

body,
and
the
electrical/pneumatic
actuating
components
.

See
Fig
.
4
.

r

I

I

I

?
,
in
UpPer,
take
-1
manifold

1
-1
Throttle
housing
(Heated)

q
:lZU

Fig
.
4
.



DISA
system
components
.
DISA
changes
the
intake
runner

length
based
on
engine
speed
.

The
DISA
system
electro-pneumatically
changes
the
intake
runner
length
through
the
twin-section
intake
manifold
and
a
change-over
butterfly
valve
.
The
change-over
valve
is
located
at
a
point
in
the
intake
manifold
where
four
pipes
come
into
two
.
When
the
change-over
valve
is
closed,
the
4-way
primary
intake
manifold
and
the
2-way
ram
air
manifold
areconnected
to
make
the
"long"
configuration
.
When
the
change-overvalve
opens,
intake
air
flow
is
redirected
through
only
the
short
4-

way
primary
intake
manifold
.

The
change-over
valve
is
held
in
the
normally
open
position
bya
spring
.
Thisallows
for
an
open
valve
in
the
event
of
sys-
tem
failure
.
During
low
andmid
enginespeeds,
the
DME
con-

trol
module
supplies
power
to
the
solenoid
valve,
which
in
turn

allows
vacuum
to
be
applied
lo
the
vacuum
diaphragm
.
This

causes
the
valve
to
close
(long-pipe
configuration)
.
When
en-
gine
speed
reaches
approximately
4,800
rpm,
the
DME
con-
trol
module
electrically
signals
the
solenoid
valve
and
the
valve
opens,
creating
the
short
pipe
configuration
:

Further
detafs
on
DISA
canbefound
in
130
Fuel
Injection
.

Engine
Management
System

Al¡
enginescoveredby
this
manual
usean
advanced
engine

management
system
called
Digital
Motor
Electronics
(DME)
.

In
the
DME
system,
advancedOn-Board
Diagnostics
(OBD),

fuel
injection,
ignition,
and
otherfunctions,
are
combined
under

the
control
of
theEngine
Control
Module
(ECM)
.
See
Fig
.
5
.

-



Lower
intake
manifold

DISAvacuum
'
~servo

EíY1z

ENGINE-GENERAL
100-
3

le

-
DISA
solenoid
valve

0012591

/
with
butterfly
va¡

GENERAL

ignition

Table
b
.
Engine
Management
Systems



engine
has
high
mileage
.

Engine



1
System

4-cylinder
engines
M42
(1992-1995)



Bosch
DME
Ml
.7
M44
(1996-1998)



Bosch
DME
M5
.2
(OBD
II)

6-cylinder
engines
M50
(1992)



Bosch
DME
M3
.1
M50
VANOS
(1993-1995)



Bosch
DME
M3
.3
.1
M52
(1996-1998)



Siemens
MS41
.1
(OBD
II)
S50US
(1995)



Bosch
DME
M3
.3
.1
S52US
(1996-1998)



Siemens
MS41
.1
(OBD
II)

Both
the
4-cylinder
and
6-cylinder
engines
use
a
distributor-

less
ignition
system
with
individual
ignition
coils
for
each
cylin-

der
.

FuelDelivery

Pressurized
fuel
from
the
in-tank
fuel
pump
is
injected
via

solenoid-type
fuel
injectors
.
The
ECM
controls
the
opening

and
closing
of
the
injectors
by
switchingthe
ground
side
of

each
injector
circuit
.
The
exact
amount
of
fuel
injected
is
de-

termined
by
the
amount
of
timethe
injectors
are
open
.

Cooling
System

Whenever
the
engine
is
running,
acoolant
pump
circulates

coolant
through
the
engine
and,
if
either
heater
control
valves

are
open,
through
the
heater
core
in
the
passenger
compart-

ment
.
The
coolant
absorbs
excess
heat
and
carries
it
to
the
ra-

diator
where
it
is
transferred
into
the
passing
airstream
.
A

thermostat
controls
the
flow
of
coolant
through
the
radiator

based
on
engine
temperature
.

Lubrication
System

The
lubrication
system
is
pressurized
whenever
theengine

is
running
.
The
oil
pump
draws
oil
through
a
pickup
in
the
bot-

tom
of
the
oil
pan,thenforces
it
through
a
replaceable
oil
filter

and
finto
the
engine
oíi
passages
.

On
4-cylinder
engines,
the
oil
pump
is
mounted
to
the
front

engine
cover
.
On
6-cylinder
engines,thechain-driven
oil

pump
is
bolted
to
the
bottom
of
the
cylinder
block
.

A
pressure
relief
valve
limits
the
maximum
system
pres-

sure
.
A
bypass
valve
prevents
the
oil
filter
from
bursting
and

insures
engine
lubrication
should
the
filter
become
plugged
.

See
119
Lubrication
System
for
additional
information
.

ENGINE-GENERAL
100-
5

Various
versions
of
DME
systems
are
usedon
thecars
cov-



MECHANICAL
TROUBLESHOOTING
ered
by
this
manual
.
See
Table
b
.
Each
system
is
highly
adaptive
to
compensate
for
things
suchasengine
wear
and



When
troubleshooting
an
engine
that
fails
to
start
or
runs
vacuum
leaks
.



poorly,
first
check
its
mechanical
condition-particularly
if
the

Warnings
and
Cautions

For
personal
safety,
as
well
asthe
protection
of
sensitive
electronic
components,
the
following
warnings
and
cautions
must
be
adhered
to
during
all
troubleshooting,
maintenance,
and
repairwork
.

WARNING
-

"
The
ignition
system
produces
high
voltages
that
can
be
fatal
.
Avoid
contact
with
exposed
termi-
nals
anduse
extreme
caution
when
working
on
a
car
with
the
ignition
switched
on
or
the
engine
running
.

"
Do
not
touch
or
disconnect
any
high
voltage
ca-
bles
from
the
coil,
distributor,
orspark
plugs
while
the
engine
is
running
or
being
cranked
by
the
starter

"
Connect
and
disconnect
the
engine
manage-
ment
system
wiring
and
test
equipment
leads
only
when
the
ignition
is
switched
off
.

"
Gasoline
is
highly
flammable
and
its
vapors
are
explosive
.
Do
not
smoke
or
work
on
a
car
near
heaters
or
other
fire
hazards
when
diagnosing
and
repairing
fuel
system
problems
.
Have
a
fire
extínguisher
available
in
case
of
an
emergency
.

"
Disconnecting
the
battery
may
erase
fault
code(s)
stored
in
control
module
memory
.
Using
special
BMW
diagnosnnc
equipment,
check
for
fault
codes
prior
to
disconnecting
the
battery
cables
.
If
the
Check
Engine
lightis
illuminated,
see
On-

Board
Diagnostics
(OBD)
forfault
code
infor-
mation
.
If
any
other
system
faults
havebeen
de-tected
(indicated
byan
illuminated
warning
light),
see
an
authorized
BMW
dealer
.

CAUTION-

"
Prior
to
disconnecting
the
battery,
read
the
bat-
tery
disconnection
cautions
gíven
at
the
front
of
this
manual
on
page
viii
.

"
Do
notconnect
any
test
equipment
that
delivers
a
12-volt
power
supply
to
terminal15
(+)
of
the
ignition
coil
.
The
current
flow
may
damage
the

ECM
.
In
general,
connect
test
equipment
only
as
specified
by
BMW,
this
manual,
or
the
equip-
ment
maker
.

"
Do
not
disconnect
the
battery
with
the
engine
running
.
Do
notrunthe
engine
with
any
of
the
sparkplug
wires
disconnected
.

MECHANICAL
TROUBLESHOOTING

100-6
ENGINE-GENERAL

Cylinder
compression,
checking

A
compression
tester
is
needed
to
make
a
compression
test
.

To
obtain
accurate
test
results,
the
battery
and
starter
must
be
capable
of
cranking
the
engine
at
250-300
rpm,
and
theen-

gine
should
be
at
normal
operating
temperature
.
Use
com-

pressed
air
to
clean
aroundthe
spark
plugs
before
removal
.

1
.
Disable
the
ignítion
system
by
removing
the
engine

management
system
main
relay
and
the
fuel
pump
re-
¡ay
.
See
Fig
.
6
.

WARNING
-

The
ignítion
system
produces
high
voltages
that
canbe
fatal
.
Avoid
contact
with
exposed
termínals
and

useextreme
caution
when
working
on
acar
wíth
the
ignítion
switched
on
or
the
engine
running
.

Fuel



DM
E
pump
main
re
ay



rel
ay
o
oa
ooa

.,
o00
oao

Fig
.
6
.



Engine
management
relays
in
power
distribution
box
inleft
rear
of
engine
compartment
.

CAUTION-

"
On
OBD
11
cars,
making
a
compression
test
may
causea
faultto
set
in
the
ECM
and
may
also
il-
luminate
the
Check
Engine
light
.
The
light
can
only
be
tumed
out
using
special
scan
tool
equip-
ment,using
eíther
the
BMW
specialservíce
tool
or
using
a
"generic"
OBD
11
scan
tool
.
Discon-
necting
the
battery
will
not
erase
the
fault
mem-
orynor
turn
outthe
light
.

0013034,

0012630

Fig
.
7
.



Remove
spark
plug
wires
from
spark
plugs
on
4-cylinder
en-
gine
using
special
tool
.
Tool
is
stored
under
cover
at
rear
of
cylinder
head
(arrow)
.

Fig
.
8
.



Remove
engine
cover
on
6-cylinder
engine
byprying
off
nut
covers
and
removing
nuts
(A)
.
Be
careful
not
to
let
rubber
in-
sulators
fall
off
as
cover
is
removed
(arrows)
.

4
.
On
6-cylinder
engines,
disconnect
the
harness
connec-
tors
from
the
ignítion
coils
by
lifting
the
retaining
clip
.

Remove
the
coil
mounting
nuts
andremove
the
six
coils
.
See
Fig
.
9
.
Remove
the
sparkplugs
.
"
Failure
to
remove
the
main
relay
or
attempting
to
disable
the
ignítion
system
by
other
methods
may
resultin
damage
to
the
engine
control
module
.



NOTE-

Used
sparkplugs
should
be
reinstalled
in
the
same
cyl-

2
.
On
4-cylinder
engine
:
Remove
plastic
engine
cover
from



inder
fromwhich
they
were
removed
.

top
of
cylinder
head
.
Disconnect
spark
plug
wires
and
re-
move
spark
plugs
.
See
Fig
.
7
.



5
.
Insta¡¡
the
compression
gauge
in
the
first
cylinder's

3
.
On
6-cylinder
engine
:
Remove
top
engine
coverby
pry-



spark
plug
hole,
tight
enough
to
form
a
good
seal
.

ing
off
nut
covers
and
removing
mounting
nuts
.
See
Fig
.
8
.

MECHANICAL
TROUBLESHOOTING

eiioo4

Fig
.
9
.



Remove
ignition
coils
on
6-cylinder
engine
by
disconnecting
harness
connector
and
removing
mounting
bolts
(arrows)
.

NOTE-

"
The
compression
gauge
reading
shoutd
increase
with
each
compression
stroke
and
reach
near
its
maxi-
mum
reading
in
about
4-6
strokes
.

"All
cylinders
shoutdreach
maximum
compression
in
the
same
number
of
strokes
.
If
a
cylinder
needs
sig-
nificantly
more
strokes
to
reach
maximum
compres-

sion,
there
is
a
problem
.

7
.
Release
the
pressure
at
the
compression
gauge
valve,

then
remove
the
gauge
from
the
spark
plughole
.
Re-

peat
the
test
for
each
of
the
other
cylinders
and
com-

pare
the
results
with
the
values
given
below
.

ENGINE-GENERAL
1
:00-
7

Compression
Pressure

"
Minimum
..........
.
.
..
..
10-11
bar
(142-156
psi)

"
Maximum
difference
between
cylinders
..
.....
.........
0
.5
bar
(7
psi)

Reinstall
the
spark
plugs
and
spark
plug
wires
or
ignition

cofs
.
The
remainder
of
installation
is
the
reverse
of
removal
.
Be
sure
to
reihstall
al¡
wires
disconnected
during
the
test,
especial-

¡y
ground
wires
at
the
coils
and
cylinder
head
cover
(where
ap-
plicable)
.

Tightening
Torque

"
Spark
plug
to
cylinder
head
.......
25
Nm
(18
ft-Ib)

Low
compression
indicates
a
poorly
sealed
combustion

6
.
With
the
parking
brake
set,
the
transmission
in
Park
or



chamber
.
Relatively
even
pressures
that
are
below
specification

Neutral,
and
the
accelerator
pedal
pressed
to
the
floor,



normally
indicate
worn
piston
rings
and/or
cylinder
walls
.
Erratic

crank
the
engine
with
the
starter
.
Record
the
highest



values
tend
to
indicate
valve
leakage
.
Dramatic
differences
be

value
indicated
by
the
gauge
.



tween
cylinders
are
often
the
sign
of
a
failed
head
gasket,

bumed
valve,
or
broken
piston
ring
.

Engine
Mechanical
Troubleshooting
Table

Table
c
lists
the
symptoms
of
common
engine
mechanical

problems,
their
probable
causes
and
the
suggested
corrective

actions
.
The
bold
type
indicates
the
repair
groups
where
appli-

cable
test
and
repair
procedures
can
befound
.

MECHANICAL
TROUBLESHOOTING

100-8
ENGINE-GENERAL

Symptom



1



Probable
cause
and
correctiveaction

1
.
Engine
will
not
start
or
run
.
Starter
cranks



a
.



No
fuel
reaching
engine
.
Check
forfuelin
tank
.

engine
at
normal
speed
.



Fuel
pump
notoperating
.
Repair
Group
160

b
.
No
spark
.
Check
ignition
system
.
Repair
Group
120

c
.
Incorrect
valve
timing
.
Check
timing
chain
.
Repair
Group
117

2
.
Check
Engine
warning
light
illuminated
.



a
.
DME
engine
management
system
self-diagnostic
fault
detected
.
Sea
an
authorized
BMW
dealer
or
other
qualified
shop
for
OBD
II
fault
code
diagnosis
.
See
also
On-
board
Diagnostics(OBD),
given
later
inthis
repair
group
.

3
.
White
exhaust
smoke
(steam)
.



a
.
Failed
cylinder
head
gasket
(probably
accompanied
bylowcompression
readings)
.

Replace
gasket
and
resurface
cylinder
head
if
necessary
.
Repair
Group
113
4
.
Blue-gray
exhaust
smoke
and
oily
spark



a
.
Contaminated
or
gasoline-diluted
engine
oil
.
Change
engine
oil
and
replace
oil
filter
.
plugs
.
Indicates
oii
burning
in
combustion
.



Repair
Group
020

b
.
Faulty
valve
guide
seals
or
valve
guides
.
Replace
valve
guide
oil
seals
or
overhaul
cylinder
head
.
Repair
Group
116

5
.
Pinging
or
rattling
when
under
load,



a
.
Ignition
timing
too
advanced
.
Ignition
knocksensors
faulty
(CheckEngine
light
traveling
uphill,
or
accelerating,
especially



illuminated)
.
Repair
Group
120fromlow
speeds
.
Indicates
pre-ignition
or



b
.
Fuel
octane
leve¡
toolow
.
detonation
.



c
.
Engine
running
too
hot
or
overheating
.
Check
cooling
system
.
Repair
Group
170

6
.
Light
metallic
tapping
that
varies
directly
with
engine
speed
.
Oil
pressure
warning
light
not
illuminated
.

7
.
Light
metallic
knock
that
varies
directly
with
enginespeed
.
Oil
pressure
warning
light
blinking
or
fully
illuminated
;
may
be
most
noticeable
during
hard
stops
or
cornering
.

8
.
Screeching
or
squealing
under
load
that



a
.
Loose,worn,
or
damaged
drive
belt
.
Inspect
belt(s)
.
Repair
Group
020
goesaway
when
coasting
.

9
.
Growling
or
rumbling
that
varieswith
engine



a
.
Remove
drive
belt(s)toidentifyfaulty
component
.
Check
for
play,
bearing
roughness,
rpm
.
Indicates
abad
bearing
or
bushing
in



and
loose
mountings
.
Refer
to
appropriate
repair
group
for
repair
procedures
.
an
engine-driven
accessory
.

DRIVEABILITY
TROUBLESHOOTING



On-Board
Diagnostics
(OBD)

On-Board
Diagnostics
is
incorporated
into
al¡
engine
man-



Two
generations
of
OBD
are
usedon
thecars
covered
by
agement
systems
used
on
the
cars
covered
by
this
manual
.



this
manual
:
Therefore,
checking
for
fault
codes
should
be
the
first
step
in
troubleshootinga
driveability
problem
.
For
additional
informa-



On-Board
Diagnostics
tion
on
engine
management
and
repair
see130
Fuel
Injec-
tion
.



"
1992-1995models
....
.
..
....
.
..
.......
OBD
I

"
1996-1998models
.
....
..
.
.
.
..
.
........
OBD
II

DRIVEABILITY
TROUBLESHOOTING

Tablec
.
Engine
Mechanical
Troubleshooting

b
.
Warped
or
cracked
cylinder
head
.
Resurface
or
replace
cylinder
head
.
Repair
Group
113

c
.
Cracked
cylinder
block
.
Replace
engine
or
short
block
.

c
.
Worn
piston
rings
.
Overhaul
or
replace
engine
.

d
.
Failed
cylinder
head
gasket
.
Replace
gasket
.
Repair
Group
113

d
.
Air/fuel
mixture
too
lean
(Check
Engine
light
illuminated)
.
Repair
Group
130

a
.
Valveclearances
excessive
.
Check
hydraulic
valve
adjusters
.
Repair
Group
116

b
.
Low
oil
pressure
orpossibly
defective
warning
light
circuit
.
Check
oil
pressure
andwarning
light
circuit
.
Repair
Group
119
c
.
Dirty
oil
.
Change
oil
.
Repair
Group
020
.

a
.
Low
oil
leve¡
.
Check
and
correct
oil
leve¡
.

b
.
Low
oil
pressure/worn
or
faulty
oil
pump
.
Oil
pump
pickup
restricted/clogged
.
Check
oil
pressure
.
Repair
Group
119

The
OBD
system
detects
emissions-related
engine
manage-
ment
malfunctions
and
tucos
on
the
Check
Engíne
lightin
the
in-
strument
cluster
.
TheCheck
Engine
light
will
stay
on
until
the
code(s)are
called
up
and
the
memory
is
erased
.
When
faulty
are
detected,
the
OBD
system
stores
a
Diagnostic
Trouble
Code
(DTC)
in
the
system
ECM
.
In
addition,
the
Check
Engine
warn-
ing
light
will
come
on
if
an
emissions-related
fault
is
detected
.

110
Engine
Removal
and
Installation

GENERAL
.
.
.
.
.......
.
.
.
..........
.
...
110-1



Engine,
removing
and
installing
(4-cylinder
engines)
.
..
.....
..
...........
110-1

ENGINE
REMOVAL
AND
INSTALLATION
110-1



Engine,
removing
and
installing
(6-cylinder
engines)
..
...
...
..
.....
..
....
110-4

GENERAL

Some
special
tools
are
required
for
removal
and
installation
of
the
engine
.
Be
sure
to
have
the
necessary
equipment
on
hand
before
starting
thejob
.

CAUTION-

"
Engine
removal
requires
disconnecting
the
bat-
tery
.
This
may
erase
any
system
fault
code(s)
that
havebeen
stored
in
control
unit
memories
.
Check
forfault
codes
prior
to
disconnecting
the
battery
cables
.

"
If
the
Check
Engine
lightis
illuminated
with
the
engine
running,
see
100
Engine-General
for
On-Board
Diagnostics
(08D)
fault
code
infor-
mation
.
"
If
any
other
system
faults
have
been
detected,
as
indicated
by
an
illuminated
ANTI
LOCK,
SRS
or
AST
warning
light,
see
the
appropriate
repair
group
inthis
manual
or
an
authorized
BMW
dealer
for
more
information
on
fault
codes
.

ENGINE
REMOVALAND
INSTALLATION

Engine,
removing
and
installing

(4-cylinder
engines)

Cover
al¡
painted
surfaces
before
beginning
theremoval

procedure
.
Asan
aid
to
installation,
label
al¡
components,

wires,
and
hoses
before
removing
them
.
Do
not
reuse
gas-

kets,
O-rings
or
seals
during
reassembly
.

WARNING
-

Due
to
risk
of
personal
injury,
be
sure
the
engine
is

cold
before
beginning
the
removalprocedure
.

1.
Disconnect
negative
(-)
cable
from
battery
in
luggage

compartment
.



0011969

CAUTION-

Prior
to
disconnecting
the
battery,
read
the
battery
disconnection
cautions
given
at
the
front
of
this
manual
on
page
viii
.

ENGINE
REMOVAL
AND
INSTALLATION



110-1

2
.
Remove
transmission
from
car
.
See230
Manual
Transmission
or
240
Automatic
Transmission
.

3
.
Remove
enginehood
or
place
hood
in
service
positíon
.
See
410
Fenders,
Engine
Hood
.

NOTE-

tt
is
notnecessary
to
remove
the
engine
hood,
but
it
is
helpful
and
will
make
engine
removal
and
installation
easier
.

4
.
Remove
splash
guard
under
engine,
if
applicable
.

5
.
Unbolt
ignition
coil
assembly
from
bracket
on
strut
tow-er
.
Disconnect
wiring
to
ignition
cofs,
then
place
coil
assembly
on
engine
.

6
.
Disconnect
al¡
cables
and
harness
connectors
at
throt-
tle
housing
.

7
.
Unbolt
andremove
complete
air
cleaner
housing
with

mass
air
flow
sensor,
disconnecting
and
labeling
con-

nectors,
ducting
and
hoses
asnecessary
.
See
Fig
.
1
.

Fig
.
1
.



Intake
air
duct
hose
clamp
(A),
mass
air
flow
sensor
connec-
tor
(B),
and
air
cleanerto
air
flow
sensor
clips
(C)
on
M44
en-
gine
.

ENGINE
REMOVAL
AND
INSTALLATION

110-2



ENGINE
REMOVAL
AND
INSTALLATION

8
.
Drain
engine
coolant
andremove
coolant
hoses
at-



10
.
Remove
radiator
cooling
fan
and
radiator
as
described

tached
to
cylinder
head
.



in
170
Radiator
and
Cooling
System
.

"
Drain
radiator
and
engine
block
.
See
170
Radiator

and
Cooling
System
.



NOTE-

"
Disconnect
hoses
from
thermostat
housing
at
front
of



Some
late
4-cylinder
modelsuse
an
electric
prímary
cylinder
head
.



cooling
fan
.
"
Disconnect
heater
hoses
at
rear
of
engine
.
See
Fig
.
2
.

CAUTION-

NOTE-



On
cars
with
viscous-type
cooling
fans,
the
radia-

"
The
block
drain
plug
is
located
on
the
exhaust
side
to-



tor
fan
has
left
hand
threads
.

wards
rear
of
engine
.

"
Remove
small
plastic
lock
clíp
to
pull
radiator
drain



11
.
Remove
upper
intake
manifold,
unfasten
cable
duct

plug
out
completely
.



from
lower
intake
manifold,
crankcase
vent
valve
hose

(M44
engine
only)

0012687

Fig
.
2
.



Coolant
hoses
at
heater
valve
and
heatercore
to
be
discon-
nected
(arrows)
.

9
.
Remove
air
shroud
from
top
of
radiator
.
See
Fig
.
3
.

ENGINE
REMOVAL
AND
INSTALLATION

12
.
Disconnect
fuel
supply
and
fuel
return
lines,
main
en-

gine
electrical
connectors,
and
lower
intake
manifold
as

described
in
113
Cylinder
HeadRemoval
and
Instal-

lation
.
See
Fig
.
4
.

0012504

Fig
.
4
.



Crankcase
ventvalve
(A)
on
top
of
lower
intake
manifoldof
M44
engine
.
Fueldelivery
and
retum
lines
shown
at
B
.
Engine
harness
and
sensor
connectors
shown
at
C
.

WARNING
-

"
Fuel
may
be
expelled
under
pressure
.
Do
not
smoke
orworknear
heaters
or
other
fire
haz-
ards
.
Keep
a
fire
extinguisher
handy
.
Before
dis-
connecting
fuel
hoses,
wrap
a
cloth
around
fuel
hoses
to
absorb
any
leaking
fuel
.
Plug
all
open
fuel
lines
.

"
Always
unscrew
the
fuel
tank
cap
to
release
pres-
sure
in
the
tank
before
working
on
the
tank
or
lines
.

CAUTION-
0013137



I
Stuff
clean
rags
into
the
open
intake
ports
topre-
Fig
.
3
.



Front
air
shroud
mounting
screws
(arrows)
.



vent
any
parts
from
falling
into
the
engine
intake
.

13
.
Disconnect
vacuum
hose
from
brake
booster
on
bulk-
head
.
Cover
bothhole
in
booster
and
plug
hose
end
.

14
.
Unbolt
power
steering
fluid
reservoir
from
íts
mounting
bracket
.
Use
stiff
wire
to
hang
reservoir
to
one
side
.
Do
not
disconnect
fluid
lines
.

15
.
Remove
power
steering
pump
drive
belt
and
remove
pump
from
its
mounting
bracket
.
Use
stiff
wire
to
hang
pump
from
body
.

16
.
On
cars
with
automatic
transmission
remove
front
and
rear
brackets
holding
automatic
transmission
cooler
linesto
engine
.

17
.
Remove
A/C
compressor
from
its
mounting
bracket
without
disconnecting
any
refrigerantlines
.
See
Fig
.
5
.

ENGINE
REMOVAL
AND
INSTALLATION



110-
3

21
.
Remove
front
exhaust
pipefrom
exhaust
manifold
.
See

Fig
.
6
.

22
.
Install
an
engine
lifting
device
and
raise
engine
until
its

weight
is
supported
.
Remove
nuts
and
ground
strap

from
left
and
right
engine
mounts
.

0011967

Fig
.
6
.



Front
exhaustpipe
to
exhaust
mounting
nuts
(arrows),
as
viewed
from
below
on
4-cylinder
engine
.

23
.
Carefully
raíse
engine
out
of
car,
checking
for
any
wir-
ing
harnesses,
fuel
lines,
or
mechanical
parts
that
might
become
snagged
as
engine
is
removed
.

24
.
Installation
is
reverse
of
removal,
noting
the
following
:

"
Replace
all
gaskets,
O-rings
and
seals
.

"
Change
engine
oil
and
filter
and
check
al¡
other
fluid
levels
.
See020
Maintenance
Program
.
"
Refill
and
bleed
cooling
system
.
See
170
Radiator
and
Cooling
System
.

"
Insta¡¡
the
front
exhaust
pipes
using
new
gaskets
and

self-locking
nuts
.
Use
copper
pasteon
threads
.
See

180
Exhaust
System
.

Tightening
Torques

"
Coolant
drain
plug
to
cylinder
block
.
25
Nm
(18
ft-Ib)

Fig
.
5
.
A/
C
compressor
mounting
bolts
(arrows)
.



"
Engine
mount
to
subframe

M8
......:...
..
..
..
......,:..
22
Nm
(17
ft
-
1b)
,

18
.
Move
A/C
compressor
out
of
way
without
distorting
or



M10
.
...
.



..
...
.
.
...........
45
Nm
(33
ft'-Ib)

damaging
any
lines
.
Support
compressor
by
hanging
it



"
Intake
manifold
to
cylinder
head

from
chassis
using
stiff
wire
.



M7
.....
.
..
...
..
..
...........
15
Nm
(11
ft-Ib)
M8
...
.
.
.
..
..
...
..
...........
22
Nm
(16
ft-Ib)

19
.
Disconnect
wiring
from
starter
and
alternator
.
Move



`
"
Radiator
cooling
fan
to
coolant
pump40
Nm
(30
ft-Ib)

wiring
harness
out
of
way
.
See
121
Battery,
Starter,



"
Radiator
drain
screw
to
radiator
...
2
.5
Nm
(22
in-lb)

Alternator
.



"
Wiring
to
alternator
(M8
nut)
........
12
Nm
(9
ft-1b)

"
Wiring
to
starter

20
.
Remove
oil
dipstick
guide
tube
.
Note
O-ring
at
base
of



M6
nut
..
.
..
..
...
..
...........
.
:5
Nm
(44
in-lb)

tube
when
removing
.



M8
nut
..
.
..
..
...
..
............
12
Nm
(9
ft-Ib)

ENGINE
REMOVAL
AND
INSTALLATION