Honda Bmw 5 Service Manual

							
Battery, Starter, ~lternatorl 
Alternator,  removing and installing 
(6-cylinder  engine) 
A replacement alternator should have  the same rating as the 
original. Alternator  manufacturer and ampere rating  are nor- 
mally marked on  the alternator housing. 
- Disconnect negative (-) battery cable. 
CAUTION- 
Prior to disconnecting  the batteg read the battery  discon- 
nection cautions given 
in 001 General Warnings  and Cau- 
I tions. 
Remove complete  air filter  housing: 
Loosen intake duct  hose clamp 
(A) at  throttle  assembly. 
Loosen  clamp and remove idle control hose from  intake 
duct 
(B) and  disconnect idle  speed control valve electrical 
harness  connector. 
Disconnect electrical harness connector 
(C) from  mass air 
flow  sensor. 
* Remove air filter  housing mounting screw (D), 
Disconnect vent tube (E). 
Loosen air intake duct clamp (F). 
Carefully  lifl air filter  housing out  of engine  bay. 
Remove alternator drive belt.  See belt removal procedures  in 
020 Maintenance. 
- Remove radiator cooling fan  and fan shroud. See 170 Radi- 
ator  and Cooling  System. 
NOTE- 
The radiator  cooling fan nut (32 mm  wrench)  has left-hand 
threads. 
- Unbolt power steering fluid reservoir and bracket. Suspend  to 
one  side  without  detaching fluid hoses. 
- Disconnect alternator  air cooling tube. 
- Disconnect  wiring from  rear  of alternator. 
4 Remove  upper and lower mounting bolts (arrows) and lift 
alternator. 
If  idler  pulley  for belt  interferes,  remove pulley cover and 
retaining  bolt to remove  pulley.  out   
						

							
121-16 
Battery, Starter, Alternator 
- installation is reverse  of removal. 
Tightening torques  Belt tensloner  to engine block 
M8 (8.8  grade)  22 
Nm  (16 ft-ib) 
Fan  clutch  to coolant pump 
with  BMW  special  tool 11 
5 040  30 Nm (22 
ft-lb) 
without  BMW special tool 
11 5 040  40  Nm 
(29 ft-ib) 
Pulley  to alternator  70 
Nm  (44 ft-lb) 
Terminal  30 
(B+) wire to alternator (M8) 13  Nm  (10 ft-ib) 
Alternator,  removing and installing 
(M62 engine,  air cooled) 
A replacement alternator should  have the same rating as  the 
original.  Alternator manufacturer  and ampere  rating are nor- 
mally 
marked on  the alternator housing. 
- Disconnect  negative (-) battery cable. 
CAUTION- 
Prior to disconnecting  the battery, read the battery  discon- 
nection cautions 
001 General Warnings  and Cautions. 
- Remove cooling fan and alternator drive  belt. See 020 Main- 
tenance. 
- Pry  out trim caps and  remove fasteners from plastic  cover on 
left  head.  Lift off cover. 
Disconnect positive 
(+) lead from jump  start post  (arrow). 
Raise car and support  in a safe manner. 
WARNING- 
Make  sure the  car is stable  and well supported  at aN times. 
Use a  professional  automotive lift 
orjack stands designed for 
the  purpose. 
A floorjack  is not  adequate  support.   
						

							
121-17 
Bauery, Starter, Alternator 
- Remove engine splash shield from underneath car. 
Working underneath car  at rear  of alternator,  loosen alterna- 
tor air cooling duct clamp 
(arrow) and  remove duct. 
Remove  three alternator mounting  fasteners 
(arrows) 
Pull alternator forward and  disconnect  wiring from rear of 
alternator. 
Release clip retaining  wiring harness  to alternator. 
Rotate alternator forward  and then  up and  out of engine  com- 
partment,  using care to not  damage  radiator. 
CAUTIOe 
Protect radiator  with heavy cardboard  or sheet  metal. 
Installation  is reverse  of removal, 
Tightening 
torques 
Fan  clutch  to coolant pump 
with  BMW  special tool 
11 5 040  30 
Nm  (22 ft-lb) 
without  BMW special tool 11 5 040 40 Nm (29 ft-lb) 
Pullev to alternator 70 Nm 144 it-lb) -, 
Terminal  30 (Bt) wire to alternator (ME) 13 Nm 110 ft-lb   
						

							
121-18 
I Battery, Starter, Alternator 
Alternator, removing and installing 
(M62 TU engine, water cooled) 
V-8 models produced  after 9/98 are equipped  with a water 
cooled  alternator. 
CAUTION- 
Allow engine  to cool  before removing alternator  as coolant 
will 
escape from the alternator water  jacket. 
- Disconnect  negative (-) battery cable 
CAUTION-  Prior  to disconnecting  the 
battew read the battery discon- 
nection cautions given  in 
001 General Warnings  and Cau- 
tions. 
- Remove  radiator  cooling fan and  fan shroud.  See 170 Radi- 
ator and  Cooling System. 
- Drain engine  cooling  system.  See 170 Radiator and Cool- 
ing  System. 
- Remove alternator  drive belt. See 020 Maintenance. 
- Disconnect  battery  lead (terminal 30 or B+) and two-pin  har- 
ness connector  from front  of alternator. 
I < Remove bolts securing alternator  to water  jacket  and remove 
aling ring 
alternator. 
NOTE-  If necessary,  raise  car and  remove  engine compartment 
splash  shield to access  lower alternator mounting bolts. 
The  upper coolant  hose can also 
be removed to  assist al- 
ternator  removal.   
						

							
Battery, Starter, Alternator 
- Installation is reverse of  removal,  noting the following: 
Replace alternator rubber sealing O-ring. 
* Fill and bleed cooling system  as described  in 170 Radiator 
and Cooling  System. 
Tightening  torques 
Fan  clutch  to coolant  pump 
with 
BMW special tool  11 5 040  30 Nm (22 ft-lb) 
without 
BMW special tool 11 5 040  40  Nm (29 ft-lb) 
Terminal 30 (Bc) wire to alternator (ME) 13  Nm  (10 ft-lb) 
STARTER 
Starter troubleshooting 
Typical  starter wiring terminal identification is  shown. Large 
wire  at terminal 
30 (not shown  in photo) is  direct battery volt- 
age.  Smaller  wire at terminal 
50 operates starter  solenoid via 
ignition  switch. 
If  starter turns engine slowly  when ignition is in start  position: 
Check  battery state  of charge. 
Inspect starter  wires, terminals, and ground 
connectlons 
for good  contact.  In particular, make sure ground  connec- 
tions between battery, body and 
englne are  completely 
clean and tight. 
If no  faults are  found, starter  may be faulty and should  be 
replaced. 
- If  starter  fails to operate, check EWS (drive-away  protection 
system).  Try another ignition  key. 
If no faults  can be  found, 
have  the EWS  system  checked  using 
BMW scan tool equip- 
ment. 
Checkclutch pedal operated 
starter lock-out switch  or gear 
position  switch (automatic). 
NOTE- 
* A factory-installed drive-away protection  system, also re- 
ferred  to as 
EWS, is used  on E39 cars.  This system  pre- 
vents  operation  of the  starter  if a specially  coded ignition 
key  is not  used. 
On  cars  with automatic  transmission, the transmission 
gear  position  switch signals 
EWS to prevent  the engine 
from starting in gear positions  other than PARK or NEU- 
TRAL. 
On cars  with manual  transmissions,  a starter immobiliza- 
tion switch 
at the clutch  pedal is used  to prevent  the starter 
from operating unless the clutch  pedal is pushed  fully to 
the  floor.   
						

							
I Battery, Starter, Alternator 
- Check for battery  voltage  at terminal 50 of starter motor with 
key  in start position.  If voltage is not present,  check wiring be- 
tween ignition switch and starter  terminal.  Check the EWS 
system and other inputs that disrupt terminal 
56 to  the  start- 
er.  See  ELE  Electrical 
Wiring Diagrams.  If voltage is 
present  and no other visible wiring  faults can be found, prob- 
lem  is most likely in starter  motor. 
Starter, removing  and  installing 
(6-cylinder  engine) 
The starter is removed  from below.  Access  to starter bolts is 
difficult. Be sure  to have the proper tools on hand before pro- 
ceeding. 
NOTE- 
Access  to the  starter  wiring is very  limited.  Forbetteraccess, 
it  may  be necessary  to remove  the intake manifold. 
- Disconnect negative (-) battery  cable. 
CAUTIOI\C 
Prior to disconnecting the battern read  the baltery  discon- 
nection  cautions 
in OOlGeneral Cautions and  Warnings. 
Remove complete air filter hous~ng: 
Loosen intake duct hose  clamp (A) at throttle  assembly. 
Loosen clamp and  remove idle control hose from  intake 
duct 
(B) and disconnect idle  speed control  valve electrical 
harness  connector. 
Disconnect electrical harness connector 
(C) from mass air 
flow  sensor. 
Remove  air filter housing mounting  screw (D) 
Disconnect  vent tube 
(E). 
Loosen air intake duct  clamp (F). 
Carefully lift air filter housing  out of engine  bay. 
Disconnect throttle cable. 
Raise vehicle and support  safely. 
WARNING- 
Make sure the car is stable  and well supported  at all times. 
Use  a professional  automotive 
lift orjack stands designed  for 
the purpose.  A 
floorjaclc is not  adequate  support 
- Working underneath  car, remove  engine splash shield 
- Disconnect fuel lines and harness connectors  from retaining 
brackets, as  necessary.   
						

							
Battery, Starter, ~lternatorl 
- Disconnect wiring from starter. 
4 Note routing for cables.  Routing varies depending on model 
and  transmission.  When  reinstalling, make sure cables do 
not  chafe. 
- Using a long  extension and universal joint  from output end of 
transmission,  remove bolts fastening starter  to transmission 
bell housing  and engine block. 
- Remove starter from below 
4 Checlc starter pinion gear and flywheel teeth  for damage. 
- Installation is reverse of removal. 
Tightening  torques 
Starter to engine 47 Nrn (35 It-lb) 
Starter sipport bracket to starter 5 Nrn (44 in-lb) 
Starter  support 
bracket to  engine 47 Nrn (35 ft-lb) 
Wlre terminals to slarter 
M5 5 Nrn (44 in-lb) 
M6 7 Nrn (62 in-lb) 
M8 13 Nrn (10 ft-lb) 
Starter, removing  and installing 
(V-8 engine) 
The starter is on the right (passenger)  side of the  engine, and 
is removed  from below. Access  to starter bolts is  difficult. Be 
sure  to have the proper tools on hand before  proceeding. 
- Disconnect negative (-) battery cable 
CA UTIOW- 
Prior to disconnecting  the battery,  read the battev discon- 
nection cautions  in 
OOlGeneral Cautions and Warnings. - 
- Raise vehicle  and support  safely. 
/ WARNING- 1 ~ ~~ ~~ ~~~ ~ 
Make sure the car is stable  and well supported  at all times. 
Use a professional  automotive lift orjacltstands designed for 
I the purpose. A floor jack is not  adequate  support I   
						

							
- 
Battery, Starter, Alternator 
- Working underneath  car, remove engine  splash shield. 
- Remove  heat shield  from starter. 
Remove starter  wire mounting nuts (arrows).  Disconnect 
wires from  starter terminals  and retaining  clip. 
Disconnect  main positive cable and bracket from suspen- 
sion. 
If  necessary  for access, remove right  side oxygen sensor 
harness  connector from  retaining clip. 
Working  from end  of transmission,  use suitable extensions 
and universal joint  to remove  starter mounting bolts  (arrows) 
at  transmission  bellhousing. 
- Remove  starter from  below. 
- Check starter pinion  gear and flywheel teeth  for damage. 
- Installation is reverse  of removal 
Tightening torques  Starter 
to engine  47 Nrn (35 
ft-lb) 
Wire  terminals  to starter 
M5 5 Nrn  (44 in-ib) 
M6 7 Nm (62 in-ib) 
ME 13 Nrn  (10 ft-lb)   
						

							
121-23 
Battery, Starter, ~lternatorl 
Solenoid switch, removing and installing 
- Remove starter  as described  previously. 
- Disconnect field winding  strap between starter  motor and 
solenoid  switch. 
NOTE- 
If the  field  winding strap  is damaged  or burned, a new  or 
rebuilt starter motor  is needed. 
< Remove  solenoid switch mounting  screws (arrows), and 
separate solenoid from starter. 
Unhoolc solenoid plunger from  lever in starter  drive 
- Installation  is reverse  of removal.  Lubricate solenoid piston 
with light  grease. 
CAUTION-  When  installing  field winding  strap to starter,  position 
itso that 
it  does not  contact the starter  body. 
Tightening  torque 
Field  strap  to starter 
13 Nm (10 ff-lb)