Engine - Repair Instructions (M42): Other BMW 3 series E36

Danger of poisoning!

Ingesting oil or absorbing through the skin may cause poisoning!

Possible symptoms are

1. Headaches
2. Dizziness
3. Stomach aches
4. Vomiting
5. Diarrhoea
6. Cramps/fits
7. Unconsciousness

Protective measures/rules of conduct

1. Pour oil only into appropriately marked containers
2. Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
3. Observe country-specific safety regulations

First aid measures

1. Do not induce vomiting.

If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of water and consult a doctor immediately.

If the person affected is unconscious, do not administer anything by mouth, place the person in the recovery position and seek immediate medical attention.

Danger of injury!

Contact with eyes or skin may result in injury!

Possible symptoms are

1. Impaired sight
2. Irritation of the eyes
3. Reddening of the skin
4. Rough and cracked skin

1. Wear protective goggles
2. Wear oil-resistant protective gloves
3. Observe country-specific safety regulations

1. Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an eye-rinsing bottle. If irritation of the eyes persists, consult a doctor.
2. Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor.

Note. Do not use solvents/thinners.

00 Safety instructions for handling oil

Recycling

Observe country-specific waste-disposal regulations.

Measures if oil is unintentionally released

1. Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work area. Wear personal protective clothing/equipment.
2. Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems, pits, cellars, water and the ground.
3. Limiting spread: Use oil blocks to prevent the surface spread of oil.
4. Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents.

Note. Do not flush oil away with water or aqueous cleaning agents.

00 00 249 BMW engine oil service (M40 / M42 / M43 / M43TU / M44)

Change engine oil and oil filter.

Version with central screw

Unscrew oil-filter cover

Oil flows from oil filter housing into oil pan.

Version with screw cap

Loosen the oil filter cap using special tool 11 7 331.

Oil flows from oil-filter housing into oil pan.

11 00 039 Checking compression of all cylinders (M40 / M42 / M43 / M43TU / M44)

1. Read out fault memory of DME control unit
2. Check stored faults
3. Rectify faults
4. Clear fault memory

Disconnect DME relay (K6300).

11 00 050 Removing and installing engine (M42)

Disconnect battery.

Disconnect battery negative pole.

Move engine hood into assembly position.

Unscrew and remove splash guard.

Remove transmission. See appropriate article in TRANSMISSIONS.

Drain coolant from engine block.

Checking valve guide (M42)

To measure, insert a new valve in such a way that the valve-stem end is flush with the valve guide.

Mount dial gauge and measure tilt clearance. Max. permissible tilt clearance < 0.5 mm (0.020").

Scheme 179

11 00 General instructions on dismantling and repairing engine block/crank drive (M42)

Note. In contradiction to the M40 engine block, the block of an M42 engine must not have a reactor for supply of oil to cylinder head.

Scheme 180

Scheme 181

Removing alternator (M42)

Unscrew earth strap.

Scheme 182

Unscrew bolts and remove alternator.

Scheme 183

Removing alternator mounting block (M42)

Unscrew and pull out oil dipstick guide tube.

Removing coolant pipe (M42)

Unscrew bolts and pull coolant pipe out of engine block.

Scheme 184

Removing crankshaft (M42)

Replace crankshaft , refer to 11 21 501

Unscrew main-bearing caps (1 ... 5) and lift out crankshaft.

Scheme 185

Removing cylinder-head cover (M42)

Unscrew cover for ignition coil.

Scheme 186

Pull off spark-plug connectors.

Scheme 187

Loosen both nuts.

Lift out complete ignition harness.

Scheme 188

Pull off hose.

Unscrew cylinder-head cover.

Removing drive belt (M42)

Loosen bolt (1).

Loosen nuts on bolts (2 and 3) and turn bolt (3) in direction of arrow to slacken drive belt.

Take off drive belt.

Scheme 189

Removing intake manifold (M42)

Unscrew upper manifold section.

Unscrew rear brace.

Pull off hose.

Scheme 190

Loosen front brace.

Scheme 191

Unscrew holder for preheater.

Removing lower timing case cover (M42)

Unscrew bolts.

Lift off timing case cover.

Note. The timing case cover can also be removed without removal of the water pump.

Scheme 192

Removing oil filter housing (M42)

Unscrew bolts and remove oil-filter housing.

Scheme 193

Removing timing case and oil pump (M42)

Unscrew all bolts.

Lift off timing case.

Removing timing chain and guides (M42)

Unscrew lower guide.

Scheme 194

Lift out chain.

Scheme 195

Remove chain guide.

Scheme 196

Removing valves (M42)

Fit special tool 11 1 065 (assembly fixture) to special tool 00 1 490 (assembly frame).

Note. Where assembly fixtures have already been supplied, screw on special tool 11 1 442 (auxiliary bracket).

Scheme 197

Install special tool 11 1 441 (support board) in assembly fixture.

Scheme 198

Mount cylinder head on assembly fixture with two cylinder-head bolts.

Scheme 199

Screw on special tool (bracket) 11 1 051.

Fit special tool 11 1 068 (pressure lever) to special tool 11 1 052 (pressure cage) and special tool 11 1 067 (guide rod).

Scheme 200

Compress valve springs and take out valve collets.

Compress valve springs and remove valve collets.

Take tray out of assembly fixture from below and pull out valve.

Scheme 201

Removing water pump (M42)

Hold pulley tight on drive belt and unscrew bolts.

Replacing / checking piston rings (M42)

Remove piston rings with a piston-ring compressing pliers.

Note. It might not be possible to find the identification on used piston rings. Lay piston rings to one side in correct sequence and installation position.

Scheme 202

Replacing connecting-rod bearing shells (M42)

Select new bearing shells according to paint mark on connecting rod.

Also refer to section on replacing main-bearing shells

Scheme 203

Replacing pilot bearing in crankshaft (M42)

Remove thrust bearing with special tool 11 2 340 and/or with special tool 11 2 010.

Scheme 204

Replacing spray jets in crankcase (M42)

Note. Spray jets are installed in bores of crankcase for bearings 2-3-4-5 and serve lubrication of piston pins and cooling of pistons. Pull spray jet out of bore.

Spray Jet Assembly

1. Nozzle housing
2. Nozzle
3. Spring
4. Ball

Scheme 205

11 14 151 Replacing crankshaft radial seal (transmission side)

Note. This repair instruction is valid for the following engines: M40 / M42 / M43 / M43TU / M44 M50 / M52 / M52TU / M54 / M56 S52 / S54

Necessary preliminary tasks

1. Remove gearbox
2. Drain off engine oil
3. Remove flywheel

Unfasten oil sump screws on transmission end.

Loosen oil pan.

Scheme 206

Release screws in end cover at rear.

Carefully detach oil sump gasket from end cover, remove end cover.

Note. After removing end cover: check oil sump gasket for damage. If necessary, remove oil sump and replace oil sump gasket.

Scheme 207

Note. As from 4/98, a new type of radial seal is used in the Series and as a replacement. This radial seal may only be supported with a "support bushing". If the radial seal is supported without the support bushing (1) for more than six months, operational reliability will no longer be assured and the radial seal must not be used any further.

Scheme 208

Distinguishing feature

1. New version "without hose spring"
2. Old version "with hose spring"

Scheme 209

Note. The end cover is offered in the kit with a radial seal.

If necessary, lift out the radial sealing ring and drive in new sealing ring using special tool 11 1 260 in conjunction with special tool 00 5 500.

Scheme 210

Check dowel sleeves (1) for damage and correct installation position.

Replace seal (2).

Apply thin, uniform coat of Drei Bond 1209 sealing compound to edges of joint on oil pan.

Scheme 211

Scheme 212

Note. When fitting the end cover with radial seal on the crankshaft, it is only permitted to use the "support bushing (1)" as an installation tool.

Lubricate contact face of crankshaft.

Scheme 213

Note. Screw threads (1) are coated with sealing compound.

Replace screws (1).

Insert all screws and tighten down end cover.

Scheme 214

Note. Keep the support bushing (1) of the new radial seal version as a "special tool", then render the special tool 11 2 213 unusable and dispose of it. The old and new radial seal versions can be installed with the support bushing (1).

Scheme 215

11 21 501 Replacing crankshaft - crankshaft removed (M42)

Note. Replacement crankshafts are supplied complete with corresponding main and connecting-rod bearing shells.

Crankshaft identification

(cast on crank)

M42 B18 = 81 mm stroke

Scheme 216

The crankshaft is surface treated and may only be reground in the factory.

Reground crankshafts are marked with stripes of paint

refer to ENGINE - TECHNICAL DATA (M42)

1. Coat of paint: Size 1
2. Coats of paint: Size 2

refer to ENGINE - TECHNICAL DATA (M42)

Scheme 217

Cars with manual transmission: Install guide bearing for transmission main shaft.

Scheme 218

Drive in pilot bearing with special tool 11 2 350 or with special tool 11 2 030 in conjunction with special tool 00 5 500 (handle).

Scheme 219

Crankshafts are marked with yellow, green or white paint depending on main-bearing-journal tolerances.

Scheme 220

Bearing shells are marked with yellow, green or white paint.

1. = Bearing shell 1-2-3-4-5 (5 only cap)
2. = Bearing shell 4 (thrust bearing, only crankshaft)

Check grinding size of main-bearing journals!

Scheme 221

Installing procedure

Only place bearing shells with "yellow" color code in the crankcase (regardless of paint mark still on the crankcase).

Install "yellow-green-white"

Install "yellow or green or white" bearing shells in bearings caps depending on the crankshaft bearing journal color code mark.

Scheme 222

11 21 531 Replacing all main crankshaft bearing shells (M40/M42)

(Engine dismantled)

Note. When crankshaft or main bearing shells are being replaced, the classification for the arrangement of the main bearing shells in the crankcase is no longer of significance. Install yellow main bearing shells in crankcase.

Note. Guide bearing shell installed at bearing No. 4 is sole means of axial alignment for crankshaft. Insert pilot bearing shell in the engine block.

Scheme 223

Install crankshaft.

Note. The crankshaft is marked with yellow, green or white paint according to the tolerance of the main journal.

Note. Place main bearing shells with same color code as that of crankshaft in main bearing caps.

Note. Main bearing caps 1 ... 3 bear identification markings on exhaust side. The main bearing caps 4 and 5 are not marked. Main bearing cap 4 has a machined shoulder on the end face.

Scheme 224

Check main bearing clearance

Place special tool 00 2 590 (Plastigage model PG 1) on oil-free crankshaft.

Do not turn crankshaft.

Place main bearing caps in position with grooves of all caps on same side.

Align main bearing cap flush with side of bearing seat.

Note. To check main bearing clearance, use old main bearing screws. No oil is permitted in the blind bores (danger of cracking). Wash and oil main bearing screws.

1. Tighten the main bearing bolts to joining torque.
2. Tighten main bearing bolts with special tool 11 2 110 or with special tool 00 9 120 with torsion angle.

Tightening Torque

refer to ENGINE - TORQUE SPECIFICATIONS (M42)

Remove main bearing cap and read off main bearing clearance from width of crushed plastic thread with measuring scale.

Main bearing clearance

refer to ENGINE - TECHNICAL DATA (M42)

If necessary, fit new bearing shells with a different color code to correct bearing clearance.

Summary

Color Code/Shaft Diameter/Bearing Shell Thickness Survey

Ge= Yellow

Gn= Green

Wh=White

1. Crankshaft
2. Main bearing clearance
3. Main bearing shells: yellow, green or white
4. Main bearing cover

11 31 091 Removing and installing or replacing chain tensioning device (M42)

Unfasten screw plug and remove hydraulic chain tensioner.

Note. The hydraulic chain tensioner can also be removed if the timing-case cover is removed.

Scheme 225

Note. When replacing the unit, installation of the M44 hydraulic chain tensioner is also permissible. The procedure for the hydraulic chain tensioner (M44) is described in the operation 11 31 091 (M44) below.

Differentiating features

The outer sleeves differ from one another. When extended, the groove is visible in version (1).

Hydraulic chain tensioner (1) can be dismantled (M42)

Hydraulic chain tensioner (2) cannot be dismantled (M44)

Scheme 226

Unscrew oil-filter cover

Note. Oil flows from oil-filter housing into oil pan.

Loosen the oil filter cap using special tool 11 7 331.

Note. Oil flows from oil-filter housing into oil pan.