Alternator, removing and installing (6-cylinder engine)
A replacement alternator should have the same rating as the original. Alternator manufacturer and ampere rating are normally marked on the alternator housing.
-Disconnect negative (-) battery cable.
CAUTION-
Prior to disconnectingthe batteg readthe battery disconnection cautionsgiven 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.
'4Remove upper and lower mounting bolts (arrows)and lift out alternator.
If idler pulley for belt interferes, remove pulley cover and retaining bolt to remove pulley.
121-16
Battery, Starter, Alternator
-
installation is reverse of removal.
Tightening torques
Belt tensloner to engine block
22 Nm (16 ft-ib)
M8 (8.8 grade)
Fan clutch to coolant pump
30 Nm (22ft-lb)
with BMW special tool 11 5 040
without BMW special tool 1 1 5 040
40 Nm (29 ft-ib)
Pulley to alternator
70 Nm (44ft-lb)
Terminal 30 (B+) wire to alternator (M8)
13 Nm (10ft-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 normally marked on the alternator housing.
-Disconnect negative (-) battery cable.
CAUTION-
Prior to disconnecting the battery, readthe battery disconnection cautions 001 General Warnings a n d Cautions.
-Remove cooling fan and alternator drive belt. See 020 Maintenance.
-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 professionalautomotivelift 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 alternator 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 compartment, using care to not damage radiator.
C A U T I O e
Protect radiator with heavy cardboard or sheet metal.
Installation is reverse of removal,
Tightening torques
Fan clutch to coolant pump
30
Nm (22ft-lb)
with BMW special tool 11 5 040
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
IBattery, Starter, Alternator
Alternator, removing and installing (M62TU 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 waterjacket.
Disconnect negative (-)battery cable
CAUTION-
Prior to disconnecting the battew read the battery disconnection cautions given in 001 General Warnings and Cautions.
Remove radiator cooling fan and fan shroud. See 170 Radiator and Cooling System.
Drain engine cooling system. See 170 Radiator and Cooling System.
-Remove alternator drive belt. See 020 Maintenance.
-Disconnect battery lead (terminal 30 or B+) and two-pin harness connector from front of alternator.
I < Remove bolts securing alternator to water jacket and remove 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 alternator removal.
aling ring
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 voltage. 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 connections 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 equipment.
Checkclutch pedal operatedstarter lock-outswitch or gear position switch (automatic).
NOTE-
*A factory-installed drive-awayprotection system, also referred to as EWS, is used on E39 cars. This system prevents 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 immobilization switchat the clutch pedalis usedto prevent the starter from operating unless the clutch pedal is pushed fully to the floor.
IBattery, Starter, Alternator
-
Check for battery voltage at terminal 50 of starter motor with key in start position. If voltage is not present, check wiring between ignition switch and starter terminal. Check the EWS system and other inputs that disrupt terminal 56 to the starter. See ELE Electrical Wiring Diagrams. If voltage is present and no other visible wiring faults can be found, problem 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 proceeding.
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 disconnectingthe battern read the baltery disconnectioncautions inOOlGeneral Cautionsand 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.
Disconnectelectrical 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 supportedat all times. Use a professionalautomotive lift orjack stands designedfor 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 universaljoint 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 sipportbracket to starter
5 Nrn (44 in-lb)
Starter support bracket to engine
47 Nrn (35 ft-lb)
Wlre terminals to slarter
5 Nrn (44 in-lb)
M5
M6
7 Nrn (62 in-lb)
M8
13 Nrn (10ft-lb)
Starter, removing and installing (V-8engine)
The starter is on the right (passenger)side of the engine,and is removedfrom below. Access to starter bolts is difficult. Be sure to have the proper tools on hand before proceeding.
-Disconnect negative (-) battery cable
CAUTIOW-
Prior to disconnectingthe battery, read the battev disconnection cautions in OOlGeneral Cautions and Warnings.
-
-Raise vehicle and support safely.
/
WARNING-
1
Make sure the car is stable and well supportedat all times.
I
Use a professionalautomotive lift orjacltstands designedfor
I
the purpose. A floor jack is not adequate support
-
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 suspension.
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 (35ft-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-
Wheninstallingfieldwindingstrap to starter,positionitso that it does not contact the starterbody.
