Engine - Repair Instructions (M42): Removal & Installation BMW 3 series E36

Installation

Replace sealing ring.

Tightening Torque

refer to ENGINE - TORQUE SPECIFICATIONS (M42) .

Scheme 85

Replace sealing ring in oil-filter cover and sealing ring on bolt.

Scheme 86

Remove oil filter insert.

Scheme 87

Tightening Torque

refer to ENGINE - TORQUE SPECIFICATIONS (M42) .

Scheme 88

Replace seals and coat with oil.

Scheme 89

After draining oil from oil-filter housing, unscrew oil drain plug or draw out oil with a vacuum unit.

Replace sealing ring.

Tightening Torque

refer to ENGINE - TORQUE SPECIFICATIONS (M42)

Scheme 90

Pour in engine oil.

Start engine and allow to idle until oil indicator light goes out.

Stop engine and check oil level.

E36 installation location

1. In file for
2. Electrical Troubleshooting Manual
3. Component location index

E46 installation location

1. Connect DIS Tester
2. Select Diagnosis
3. Carry out vehicle identification
4. Function selection
5. Component and signal function
6. Components
7. Relays
8. DME relay
9. Documents
10. Installation location (IL)
11. Displays

Remove all spark plugs

refer to ENGINE - TECHNICAL DATA (M42) .

Screw special tool 11 0 226 by hand into spark plug thread and connect special tool 11 0 224.

Note. Check that seal is in perfect condition.

Scheme 91

Depress accelerator and actuate starter until compression stops rising.

Compression pressure

refer to ENGINE - TECHNICAL DATA (M42) .

Scheme 92

Now clear the fault memory.

Scheme 93

1. Connect DIS tester
2. BMW measuring technology
3. Preset measurements
4. Absolute compression The further procedure is described in Help Help on preset measurements Adaptation of "Absolute compression"
5. Clear fault memory

Replace seal.

Tightening torque

refer to Technical Data ENGINE - TORQUE SPECIFICATIONS (M42)

Scheme 94

Remove fan cowl and radiator

Remove intake filter housing.

Brace pulley with special tool 11 5 050 (bracket) and unfasten cap nut from water pump with special tool 11 5 040.

Scheme 95

Tighten fan using special tool 11 5 040.

Tightening torque

refer to ENGINE - TORQUE SPECIFICATIONS (M42)

When using special tool 11 5 040, 30 Nm on the torque wrench scale are equivalent to a tightening torque of 40 Nm.

Scheme 96

Disconnect coolant hoses on engine.

Scheme 97

Disconnect heater hoses at heater and heating valve.

Top and drain cooling system.

Scheme 98

Pull adapter out of brake booster.

Scheme 99

Disconnect Bowden cable for throttle valve actuation.

Remove alternator drive belt.

Unscrew power steering oil supply tank from left-hand engine carrier and tie back to one side.

Scheme 100

Unscrew power steering pump from engine and tie back to one side.

Note. Lines remain connected.

Scheme 101

Unfasten fuel delivery and fuel return lines.

Remove ignition coils

Removing upper section of manifold.

Remove plug connection on idle speed actuator.

Scheme 102

Pull off hose to filter for tank ventilation.

Scheme 103

Unfasten cable duct on lower section of manifold.

Scheme 104

Remove oil dipstick guide.

Check O-ring, replace if necessary.

Scheme 105

Remove lower manifold support.

Unscrew manifold lower section.

Replace seals.

Note dowel sleeves (3) and (4).

Scheme 106

Unfasten engine section of wiring harness and place to one side with cable duct.

The plug and screw connections are described in the section on replacing the engine section of the wiring harness

Attach engine to special tool 11 0 070 (engine hoist).

Scheme 107

Front and rear suspension arrangement

Scheme 108

Unfasten right ground wire.

Unfasten left and right engine mounts.

Lift out engine.

Scheme 109

Replace nuts. Coat threads with copper paste.

For tightening torque , refer to ENGINE - TORQUE SPECIFICATIONS (M42) .

Scheme 110

Replace seals.

Beads of seals face the exhaust manifold.

Scheme 111

Secure engine to special tool 00 1 490 (assembly frame) with special tool 11 0 090 (locating plate).

Scheme 112

Replace sealing ring.

Scheme 113

Press out sleeve.

Unscrew bolts and remove mounting block.

Scheme 114

Replace and lubricate O-ring with a lubricant.

Scheme 115

Bearing caps 1 ... 3 are marked with die-stamped numbers.

Bearing cap 4 has a shoulder on the cap side. Bearing cap 5 is not marked.

Scheme 116

Ensure that the oil spray jets are used at bearings 2 ... 5.

Scheme 117

Lubricate bearing shells.

Install crankshaft.

Mount bearing caps 1 ... 5 (bearing No. 1 at camshaft-drive end) in such a way that grooves of bearing-shell guide are on one side.

Align bearing caps precisely.

Note. The thrust bearing shell is installed only in the crankcase at bearing No. 4

Scheme 118

Bearing-cap tightening procedures

Tighten bolts (washed and lubricated with oil) in two steps.

For tightening torque , refer to ENGINE - TORQUE SPECIFICATIONS (M42) .

Scheme 119

For tightening torque , refer to ENGINE - TORQUE SPECIFICATIONS (M42)

Scheme 120

Note. Cylinder-head cover is separated from cylinder head by rubber mounts and seals to prevent oscillation.

Note arrangement of rubber mounts.

Scheme 121

Check seals, replace if necessary.

Scheme 122

Check for correct seating of seal on back of cylinder head when installing cylinder-head cover.

Scheme 123

Adjust Vee-belt tension with special tool 11 5 020 by rotating screw (3) in direction of arrow.

Tighten nut on bolt (3).

Tighten bolts (1 and 2).

Scheme 124

If applicable, bend holder for preheater far enough for bearing surface of preheater to bear firmly on throttle-valve assembly.

Scheme 125

Unscrew bolts.

Scheme 126

Lift off upper intake-manifold section.

Pull hose off fuel-pressure regulator at the same time.

Scheme 127

Replace seal.

Check dowel sleeves.

Scheme 128

Pull connecting strip off fuel injectors.

Scheme 129

Unscrew clamp.

Scheme 130

Unscrew bolts.

Pull off injection pipe together with fuel injectors.

Lubricate sealing rings lightly with oil.

Scheme 131

Unscrew lower manifold section.

Scheme 132

Replace seal.

Check dowel sleeves.

Scheme 133

Replace seals.

Check dowel sleeves.

Scheme 134

Press new radial seal down flush with pressure ring on special tool 11 1 270 in conjunction with central screw and washer with timing case cover fitted.

Scheme 135

Replace O-ring and seal.

Coat O-ring with a lubricant.

Tightening torque 9 Nm

Scheme 136

Check location of socket head bolts.

Upper left bore (1) is not used.

Tighten all bolts uniformly.

For tightening torque , refer to ENGINE - TORQUE SPECIFICATIONS (M42) .

Scheme 137

Chain lubrication spray jet faces bolt.

Scheme 138

Replace seal.

Check dowel sleeves.

Scheme 139

Align and bolt chain guide only after installation of the cylinder head and complete chain system.

Scheme 140

If applicable, remove tensioning rail.

Scheme 141

Pull sprocket off the crankshaft. Lift out woodruff key.

Scheme 142

If applicable, remove reversing roller.

Scheme 143

Note. Reversing roller may be replaced only complete with the bearing.

Scheme 144

If one spring of the spring set (inner or outer spring) is damaged or broken, both springs must be replaced.

Only use inner and outer springs of the same make and with the same color code.

Installation sequence

1. Valve
2. Valve-stem seal
3. Spring retainer, outer spring
4. Spring retainer, inner spring
5. Outer spring
6. Inner spring
7. Spring retainer, top
8. Valve collets

Scheme 145

Exhaust valves are filled with sodium to improve heat deflection.

Sodium filled valves may not be disposed of as normal parts without special treatment. The reason for this is that sodium could explode when melted. It is also not permitted to use them as "special tools" - such as, for example, impact mandrels - as is common in some workshops.

Scheme 146

Pull off valve-stem seal with Special Tool 11 1 250.

Scheme 147

Lubricate valve stem with oil and insert valve.

Apply Special Tool 11 1 380.

Lubricate new valve-stem seal with oil and install.

Scheme 148

Press on valve-stem seal by hand against stop with help of special Tool 11 1 200.

Scheme 149

Align dowel-pin bore in vibration damper with dowel pin.

Tightening torque 23 Nm.

Scheme 150

Tightening torque 9 Nm.

Scheme 151

Unscrew bolts.

Tightening torque 9 Nm.

Scheme 152

Tighten 2 M6 screws into the thread and force water pump evenly out of end cover.

Scheme 153

Replace and lubricate O-ring with a lubricant.

Tightening torque 9 Nm

Scheme 154

Insert piston rings with "TOP" facing piston crown.

1. Rectangular section ring
2. Taperface ring
3. Steel band ring (oil scraper ring)

Arrange piston ring contact points with offset of approx. 120° to one another - but not over piston pin eye.

Scheme 155

The oil scraper ring consists of two steel band rings (1) and one spring ring (2).

Install all parts separately.

Offset contact points at approx. 120° intervals.

Scheme 156

Measure side clearance

Specification , refer to ENGINE - TECHNICAL DATA (M42) .

Scheme 157

Measure end clearance

Specification , refer to ENGINE - TECHNICAL DATA (M42) .

Scheme 158

Check conrod-bearing play. Only carry out for control purposes.

For BDC piston setting, place Plastigage (type PG1, special tool 00 2 590 ) on the oil-free crankshaft.

Mount conrod-bearing caps and tighten with old conrod bolts tightened to specified torque. See ENGINE - TORQUE SPECIFICATIONS (M42)

Scheme 159

Remove bearing cap and read bearing play

refer to ENGINE - TECHNICAL DATA (M42)

Measure width of the flattened Plastigage with help of the supplied scale.

Install new bearing shells or bearing shells with a different color code to correct the bearing play.

Scheme 160

Install thrust bearing and drive firmly home with special tool 11 2 350 and/or with special tool 11 2 030.

Scheme 161

Ensure that the oil spray jets are used at bearings 2 ... 5.

Check bearing clearance

Only carry out this step for control purposes.

Install crankshaft. Place Type PG 1 Plastigage (Special Tool 00 2 590) on crankshaft wiped clean of oil and tighten bearing cap bolts as specified. For tightening torque

refer to ENGINE - TORQUE SPECIFICATIONS (M42)

Do not turn crankshaft.

Scheme 162

Remove bearing cap and read bearing clearance

refer to ENGINE - TECHNICAL DATA (M42) .

Read according to width of the flattened Plastigage with help of supplied scale.

Install new bearing shells or bearing shells with a different color code to correct the bearing play.

Scheme 163

Overview

Color Code/Shaft Diameter/Bearing Shell Thickness Survey

Triple-classification color codes

Ge Yellow

Gn Green

Wh White

1. Crankshaft
2. Bearing play
3. Bearing-shell thickness
4. Journal diameter

Scheme 164

Replacing conrod bearing shells

Red or blue conrod bearing shells are installed as standard according to the colour-code mark on the connecting rod for a relevant grinding size or crankshaft.

Install only red bearing shells of the relevant grinding size for replacement crankshafts.

Check conrod-bearing play.

Only carry out for control purposes.

For BDC piston setting, place Plastigage (type PG1, special tool 00 2 590 ) on the oil-free crankshaft.

Mount conrod-bearing caps and tighten with old conrod bolts tightened to specified torque. See ENGINE - TORQUE SPECIFICATIONS (M42)

Remove bearing cover and read off bearing clearance

refer to ENGINE - TECHNICAL DATA (M42)

Measure width of squashed plastic thread with help of measuring scale.

Install new bearing shells or bearing shells with a different color code to correct the bearing play.

Bearing-cap tightening procedures

Tighten down screws (washed and oiled) in 2 passes.

Tightening torque , refer to ENGINE - TORQUE SPECIFICATIONS (M42)

Connecting-rod-bearing-cap bolt tightening procedure

Lubricate conrod-bearing shells with oil.

Mount bearing cap so that pair numbers are aligned.

Install new connecting-rod bolts.

Tighten conrod screws in two passes using special tool 00 9 120 or with special tool 11 2 110

Tightening torque , refer to ENGINE - TORQUE SPECIFICATIONS (M42)

Scheme 165

Remove plastic thread.

Coat main bearing shells and crankshaft with engine oil.

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

Align main bearing cap flush with side of bearing seat.

No oil is permitted in the blind bores (danger of cracking).

Replace, wash and oil main bearing bolts.

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)

Check axial play.

End float

refer to ENGINE - TECHNICAL DATA (M42)

If necessary, check the guide bearing shell, crankshaft and engine block.

Scheme 166

The hydraulic chain tensioner must be dismantled and relocked in transport position (installation position).

Strike the outer sleeve of the hydraulic chain tensioner against a hard surface.

This releases the interlock and causes the hydraulic chain tensioner to jump apart.

Scheme 167

Arrangement of components

1. Outer sleeve
2. Spring
3. Hydraulic piston
4. Detent ring
5. Snap ring for locating in transport position (installation position)

Scheme 168

Secure hydraulic chain tensioner with protective jaws in vise.

Insert detent ring (4) in groove of hydraulic piston.

Scheme 169

Compress hydraulic chain tensioner slowly and carefully until detent ring (4) locates against slip taper on outer sleeve.

Press ends of detent ring (4) into slip taper of outer sleeve.

Scheme 170

Carefully and slowly compress hydraulic chain tensioner until snap ring (5) audibly locates in transport position (installation position).

Scheme 171

Scheme 172

Insert the hydraulic chain tensioner; replace the sealing ring of the drain plug.

Tighten the drain plug.

Tightening torque

refer to ENGINE - TORQUE SPECIFICATIONS (M42)

The hydraulic chain tensioner must be unlocked.

Press tensioning rail briefly against the hydraulic chain tensioner, thereby unlocking the hydraulic piston which returns to its functional setting.

If necessary, when timing case cover is fitted, disengage by pressing briefly counter-engine wise.

Scheme 173

Note. After disassembly, the hydraulic chain tensioner has no oil fill and must be operated for approx. 20 seconds at 3500 RPM with vehicle stationary to ensure functional safety.

Replace sealing ring.

Tightening Torque

refer to ENGINE - TORQUE SPECIFICATIONS (M42) .

Replace sealing ring in oil-filter cover and sealing ring on bolt.

Check/replace sealing rings on special tool 11 4 170.

Install special tool 11 4 170.

Tightening Torque

refer to ENGINE - TORQUE SPECIFICATIONS (M42) .

Scheme 174

Connect special tools 13 3 061 / 063.

Start engine and check engine oil pressure

refer to ENGINE - TECHNICAL DATA (M42) .

Scheme 175

Tightening Torque

refer to ENGINE - TORQUE SPECIFICATIONS (M42) .

Replace sealing rings.

Check seals on special tool 11 7 332 and replace if necessary.

Scheme 176

Instead of the oil filter cover, screw special tool 11 7 332 onto the oil filter housing and tighten using special tool 11 7 331.

Tightening Torque

refer to ENGINE - TORQUE SPECIFICATIONS (M42) .

Connect special tools 13 3 061 / 063.

Start engine and check engine oil pressure

refer to ENGINE - TECHNICAL DATA (M42) .

Scheme 177