Removing and installing the BMW E36 engine
The BMW E36 engine is disassembled without a gearbox and taken upwards. The intake and exhaust manifolds and the alternator remain on the engine. A hoist is required to remove the motor. Due to the need to disconnect several elements from the chassis, four car jacks and a hydraulic jack are needed. Before starting work, the fenders should be covered.
Depending on the year of production and equipment of the car, electric cables, the vacuum and coolant lines can be routed differently. Because not all variants can be described in detail, it is recommended to label each wire with colored adhesive tape before disconnecting it. Engine disassembly for 316i and 318i versions is described in detail (4 cylinder engines), as well as 320i and 325i (6 cylinder engines), Since September 1993 in versions 3161 and 318i introduced a new ignition system, without distributor, and changed the intake pipe.
Removing the BMW E36 engine
• Remove the gearbox (see "Gearbox").
• Leave the car.
• Put the engine compartment cover in the installation position, that is, vertically. To do this, release the catch (the arrow in fig. W-10148) and pull the cover upwards.
Caution. Do not operate the wipers after the bonnet is in the installation position, wiper blades may scratch the cover. To be sure, remove the appropriate fuse.
• Disconnect the workpiece lead and positive lead from the battery.
Caution. This will erase the anti-theft security code for the radio. The battery cables can then be disconnected, when the ignition is off. Otherwise the injection system control device will be damaged.
Before disconnecting the battery, read the instructions in the chapters "Removing and installing the radio" and "Removing and installing the battery". Caution. On cars with 6-cylinder engines, the battery is located in the luggage compartment, to the right, next to the spare wheel.
• Remove the air filter with mass air flow meter. To do this, turn the knurled nut clockwise and remove the connector.
• Open the clamp, unscrew the screws (1, Lynx. W-10149) and take out the air filter housing.
• On 6-cylinder engines: unscrew a screw (the arrow in fig. W-10150) at the bottom of the air filter housing and remove the intake air and coolant thermostat sensor.
• Disconnect from intake manifold (arrows in fig. W-10151) the hose to the idle control valve; and the crankcase ventilation hose. On a 4-cylinder engine, also disconnect the wiring harness.
• On 6-cylinder engines: unscrew and remove the air supply duct to the alternator (arrows in fig. W-1052).
• Drain the coolant (see chapter "Maintenance").
• Remove the fan (the chapter "Cooling system”).
• Remove the radiator (the chapter "Cooling system”).
Caution. If the coolant hoses are secured with clamps, cut the ties and use twisted ties for assembly.
BMW E36 4-cylinder engine
• After cutting the zip ties, disconnect the coolant hoses from the thermostat housing.
• Disconnect the coolant hose from the engine to the expansion tank.
• Remove the throttle cover. To do this, undo the screw (right arrow in fig. W-10172), tilt the cover and unscrew the other two screws (arrows in fig. W-10172).
• Disconnect the cable from the throttle (1, Lynx. W-1061), disengaging the fastening latch in the direction of the arrow. In automatic gearboxes, the cable must also be disconnected (2).
• Remove the screws (3) and put aside the cable with the handle.
• Pull out the plug (4) from the idle speed actuator connector and remove the vacuum hoses (5, 6, Lynx. W-1061).
• Loosen the fastening bands (arrows in fig. W-10170), disconnect the coolant hoses from the heating valve and remove the heater.
• Remove the fresh air inlet tray (see chapter "Heating").
• Remove the vacuum hose from the booster. This requires more force.
Caution. Cover the opening of the brake booster connection with a clean cloth.
BMW E36 6-cylinder engine
• Disconnect the cable (1, Lynx. W-10153) from the throttle lever. To do this, press the arm towards the tendon, Use a thin screwdriver to squeeze out the connector (3). Ścisnąć garby (2) the cable holder and pull them out of the throttle lever. Pull the pull rod down through the slot in the arm. Disengage the other cable in the same way (if it's) from the speed controller, as special equipment (version, as in the drawing W-10153).
• Remove the oil filler cap.
• Use a screwdriver to remove the round plugs (arrows, Lynx. W-10201) and remove the hidden screws.
• Remove the two plastic covers.
• Unscrew the workpiece lead (1, Lynx. W-10156) from the cylinder head.
• Pry off with a screwdriver and remove from the socket (2) cylinder head venting line.
• Remove the two screws (1, Lynx. W-10157) and pull the socket strip upwards, Mark the position of the rubber gasket for reassembly.
• Lift up the metal brackets (2, Lynx. W-10157) on each ignition coil and disconnect the plugs. Disconnect the complete socket strip together with the electric cables.
• Disconnect the cables and plugs from the throttle body (Lynx. W-10158), by marking them appropriately in order to avoid alterations during assembly. When removing the plugs, squeeze the elastic wire protectors.
Figure W-10158 shows a variant for a 6-cylinder engine. The remaining markings in the drawing: 1 – throttle opening sensor plug, 2 – plug of air temperature sensor, 3 – coolant lines for pre-heating the throttle, 4 – fuel tank vent hose, 5 – fuel feed line (unpainted connector), 6 – fuel return line (connector painted black).
Caution. Because there is a fire hazard, do not go near with open fire. Place rags under leaking fuel.
• Loosen the clamp and disconnect the flexible part of the fuel feed line from the rigid part (at the engine mounting beam). Place rags under leaking fuel.
• 6-cylinder engine: disconnect at the bottom, on the inlet pipe, flexible hose to the idle speed control valve.
Caution. The catch tab breaks easily. The connector is not visible from the top.
Figure W-10159 shows the intake pipe seen from the bottom.
• Unscrew the support of the intake pipe.
• Only for 6-cylinder engines: unscrew the intake manifold from the cylinder head.
Caution. Be careful, so that no small parts can get into the intake pipes, as this would seriously damage the engine.
• Squeeze the spring clips and remove the sensor connector plugs: temperature (1, Lynx. W-10162), remote thermometer (2), oil pressure (3) and the idle speed control valve (4).
• On 4-cylinder engines, also disconnect: from the ignition coil – high voltage cable, leading from the ignition distributor, fuel injector connector pins (at the end of the cable tunnel), connector plug of the fuel tank vent valve (on the line between the activated carbon tank and the inlet pipe).
• 4 cylinder engines: unscrew the fuel hose holders (the arrow in fig. W-10173).
• Disconnect the plugs on the flywheel housing: cylinder work identification sensor (1, Lynx. W-10163, black colour) and the pulse sensor of the DME Motronic system (2 – grey colour).
• Unscrew the electric wires from the alternator and starter; see also the corresponding subsections in the chapter "Electrical equipment").
• Unscrew the cable tunnel from the engine block and set aside the cable harness.
• On cars with power steering: remove the V-belt, unscrew the hydraulic pump and set aside, without removing the oil lines.
Caution. If the oil line is disconnected after finishing work, bleed the power steering hydraulic circuit (see article "Maintenance").
• Unscrew the two bolts securing the power steering oil tank on the left bracket of the engine mounting frame and hang the tank on the wire.
• Cars with air conditioning: remove the V-belt, unscrew the compressor (Lynx. W-10167) and set aside, without disconnecting the wires.
Caution. Do not unseal the refrigerant circuit. It contains freon and may cause frostbite if it comes into contact with human skin.
• Thread a suitable rope or chain through the engine mounts and use a workshop hoist to raise the engine slightly.
• Unscrew the nut of the right engine support and the ground cable (the arrow in fig. W-10169).
• In the same way, unscrew the nut of the left support.
• Check, that all hoses and electric cables have been disconnected, which connect the engine to the body. Remove the engine.
Caution. Be careful when removing the engine, to avoid damage to the bodywork.
The removed engine must not be kept longer than 10 minutes in an inverted position, as oil will leak from the hydraulic tappets that compensate the valve lash and they will no longer fulfill their functions. If it is necessary to reverse the engine, remove the pushrods.