Starters: Removal & Installation BMW 7 series E65/E66 facelift

REMOVAL & INSTALLATION

Removal

1. Remove right oxygen control sensor. See «OXYGEN CONTROL SENSOR»(ref-165804-S15548109002004090700000).
2. Remove right oxygen monitor sensor. See «OXYGEN MONITOR SENSOR»(ref-165804-S14382023202004090700000).
3. Remove complete exhaust system. See «EXHAUST SYSTEM»(ref-165804-S27862605002004090700000).
4. Remove acoustic cover. Using Special Tool (51 2 180), secure engine hood in service position. Assemble Special Tool (00 0 200) with Special Tools (00 0 201/202/203/204/208/ and attach. (Scheme 7) Secure Special Tool (11 0 000) to front and rear lifting eyes and to Special Tool (00 0 200). Supports (1) of Special Tool (00 0 208) must rest on bolt connection of both side walls.
5. Tighten screws (1 and 2). (Scheme 8)
6. Remove air cleaner element. Release retaining screws on coolant expansion tank. Remove screws and remove intake filter housing (1). (Scheme 9)
7. Lower front axle support. See «LOWERING FRONT AXLE SUPPORT»(ref-165804-S19254210162004090700000).

Scheme 7

Scheme 8

Scheme 9

1. Using Special Tool (31 2 220), support exhaust system. (Scheme 10)
2. Remove nuts of flanges on both exhaust manifolds with integrated catalytic converter. (Scheme 11)
3. Remove nuts. (Scheme 12)
4. Remove nuts. (Scheme 13) Remove reinforcement plate.
5. Remove nut. (Scheme 14) Detach rubber element from holder.
6. Remove nut. (Scheme 15) Remove holder of rear muffler.
7. Remove nut. (Scheme 16) Remove holder on tailpipe. Detach hose from vacuum unit. Carefully lower exhaust system.
8. To install, reverse removal procedure.

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

1. Remove underbody protection. Remove reinforcement plate. Unscrew and remove splash guard.
2. Secure steering wheel from turning. Release clamping screw. (Scheme 17) Detach universal joint from power steering gear.
3. Release upper clamping screw from universal joint with corrugated tube. (Scheme 18) Pull universal joint with corrugated tube downwards, gripping lower section of steering spindle while so doing. Remove universal joint with corrugated tube.
4. Disconnect plug on steering gear.
5. Support front axle with Workshop Hoist (00 2 030) and Special Tools (00 2 040, 31 4 012 & 33 3 274). (Scheme 19)
6. Insert Special Tool (31 4 012) in rear openings in front axle support. (Scheme 20)
7. Attach hydraulic jack on mounting for vehicle jack. Remove front axle support from engine support on left and right. (Scheme 21)
8. Lower bottom edge of front axle support to engine carrier no more than 6 inches (150 mm).
9. Remove A/C compressor drive belt. See «A/C COMPRESSOR DRIVE BELT»(ref-164048-S33468724522004072100000) under REMOVAL & INSTALLATION in GENERATORS & REGULATORS article. Remove screw connection of A/C compressor. Place A/C compressor to one side and secure A/C system line so as to improve access to nuts on exhaust manifold.
10. Remove nuts on exhaust manifold. Remove exhaust manifold towards bottom and pull out towards rear.
11. To install, reverse removal procedure. Replace seals. Beads of seals face exhaust manifold. Coat threads with copper paste. Tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-165804-S26646674942004090700000).

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

1. Switch off ignition. Unlock and detach plug connection (1). (Scheme 22) Unclip oxygen control sensor cable (3).
2. Using Special Tool (11 7 030), remove oxygen control sensor (2). (Scheme 23)
3. To install, reverse removal procedure. Apply a thin and uniform coat of Never Seez compound to thread. Oxygen sensor section projecting into exhaust system branch must not be cleaned or come into contact with lubricant. Using Special Tool (11 7 030), tighten oxygen control sensor to specification. See «TORQUE SPECIFICATIONS»(ref-165804-S26646674942004090700000).
4. Pay attention to cable routing of oxygen control sensor.
5. Read out fault memory of control unit of Digital Motor Electronics (DME). Rectify faults. Clear fault memory.

Scheme 22

Scheme 23

1. Switch off ignition. Unlock and detach plug connection (1) for oxygen monitor sensor (2). (Scheme 24) Unclip oxygen monitor sensor cable.
2. Using Special Tool (11 7 030), remove oxygen monitor sensor.
3. To install, reverse removal procedure. Apply a thin and uniform coat of Never Seez compound to thread. Oxygen monitor sensor section projecting into exhaust system branch must not be cleaned or come into contact with lubricant. Using Special Tool (11 7 030), tighten oxygen monitor sensor to specification. See «TORQUE SPECIFICATIONS»(ref-165804-S26646674942004090700000).
4. Pay attention to cable routing of oxygen monitor sensor.
5. Read out fault memory of control unit of Digital Motor Electronics (DME). Rectify faults. Clear fault memory.

Scheme 24

1. Turn off ignition. Remove starter. See «STARTER»(ref-165804-S29544864762004090700000).
2. Remove nut (1). (Scheme 25) Remove cable lug (2).
3. Remove screws (1). (Scheme 26)
4. Remove solenoid switch (1) and spring (2). (Scheme 27) Unhook pin (3).
5. To install, reverse removal procedure. Check pin (3) for wear and apply grease. Tighten nut for cable lug to specification. See «TORQUE SPECIFICATIONS»(ref-165804-S26646674942004090700000). Do NOT turn cable lug while tightening down.

Scheme 25

Scheme 26

Scheme 27

Note. Numbers in text apply to numbers in figures.

1. Switch off ignition. Disconnect and cover battery negative terminal.
2. Remove reinforcement plate.
3. Remove right exhaust manifold.
4. Release screw and nut. (Scheme 28) Remove heat shield (1).
5. Remove nut (2). (Scheme 29) Unlock plug (1) and remove.
6. Remove screws and pull release out of transmission mounting and remove. (Scheme 30)
7. To install, reverse removal procedure. Check starter motor pinion and ring gear for damage. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-165804-S26646674942004090700000).

Scheme 28

Scheme 29

Scheme 30