Month: October 2017

BMW 633CSi-635CSi 1978-1989

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Complete digital official shop manual contains service, maintenance, and troubleshooting information for the BMW 633CSi/635CSi 1978-1989. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for BMW 633CSi/635CSi 1978-1989is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

BMW 633CSi 1978-1984
BMW 635CSi 1985-1989

EXCERPT:
3.5L 6-CYL 1989-90 Engine – 3.5L 6-Cylinder
Removal (Manual Transmission)
1. Remove exhaust system and support brackets from vehicle. Disconnect drive shaft at rear of transmission.
Remove heat shield from center support bearing.
2. Remove center support bearing bracket. Lower drive shaft at center support bearing and pull drive shaft from transmission. Remove speed and reference mark sensors.
3. Remove clutch slave cylinder, leaving line connected. Remove speedometer cable and disconnect plug from back-up light switch.
4. Pull up boot from floor shift lever. Remove circlip and pull shift lever up and out. Support transmission and remove crossmember. Remove transmission.
Installation (Manual Transmission)
1. To install, reverse removal procedure. When installing drive shaft, use new lock nuts at rubber coupling.
Only tighten nuts (never bolts) to avoid stress on coupling.
2. When installing drive shaft, push center support bearing forward .08″ (2.0 mm) to preload bracket and tighten nuts.
3. When installing speed and reference mark sensors, note that Black plug of speed sensor faces ring gear.
Gray ring of reference mark sensor faces flywheel. If plugs are reversed, engine will not start.
Removal (Automatic Transmission)
1. Disconnect exhaust system and remove support brackets. Disconnect bracket and accelerator cable from transmission. Drain transmission oil. Remove filler tube and plug opening.
2. Disconnect oil cooler lines from transmission. Label and disconnect all wiring attached to transmission.
Remove cover plate from transmission. Mark installed positions of speed and reference mark sensors.
Remove sensors.
3. Remove 4 bolts securing torque converter to drive plate. Disconnect shift rod from lever. Disconnect drive shaft coupling at rear of transmission.
4. Remove heat shield and center support bearing bracket. Lower drive shaft at center support bearing and pull drive shaft from transmission. Support transmission.
5. Remove crossmember and lower transmission to rest on front axle carrier. Place transmission jack under transmission. Separate and remove transmission and torque converter from engine.
Installation (Automatic Transmission)
1. To install transmission and remaining components, reverse removal procedures. Before installing transmission, ensure torque converter is properly seated.
2. When installing drive shaft, push center support bearing forward .08″ (2.0 mm) to preload bracket.
Tighten nuts.
3. When installing sensors, note that Black plug of speed sensor faces ring gear and Gray ring of reference mark sensor faces flywheel. If plugs are reversed, engine will not start.
ENGINE R & I
NOTE: Vehicle transmission must be removed prior to engine removal.
Removal
1. Remove hood. Disconnect battery cables from battery. Remove transmission. Remove splash guard from under engine. Drain cooling system and remove radiator. Remove power steering pump (leaving hoses connected) and secure away from engine.
2. Remove A/C compressor with hoses connected (If equipped). Secure away from engine. Remove accelerator cable. Remove cruise control cable from engine (if equipped).
3. Label and disconnect all electrical and ignition wiring that might interfere with engine removal.
Disconnect wiring harness in glove box and pull through hole in firewall.
4. Label and disconnect all coolant, ventilation, fuel and vacuum hoses (or lines). Remove air cleaner with airflow sensor.
5. Remove nuts from engine mounts. Ensure no wiring, hoses or lines are attached to engine. Attach lifting chain and hoist to engine. Carefully lift engine from vehicle.
Installation
To install engine, reverse removal procedures. Ensure that all hoses, lines and electrical connections are installed in original positions. Bleed cooling system.
CYLINDER HEAD R & I
Removal
1. Disconnect battery ground cable. Drain cooling system. Remove splash guard from bottom of engine.
Disconnect exhaust pipes from manifolds.
2. Disconnect accelerator and cruise control cables from throttle valve housing, including cable to automatic transmission (if equipped). Disconnect attached hoses and electrical wiring. Remove air cleaner with airflow sensor.
3. Label and disconnect all coolant hoses attached to cylinder head. Label and disconnect all fuel, ventilation and vacuum hoses (or lines) from cylinder head and intake manifold.
4. Label and disconnect all electrical and ignition wiring. If necessary, disconnect electrical plug in glove box, and pull wiring through hole in firewall.
5. Remove valve cover. Set No. 1 piston on TDC of compression stroke. Timing pointer and mark on vibration damper should align. Valves of No. 6 cylinder should overlap.
6. Remove timing chain tensioner plug, spring and piston. Remove camshaft sprocket. Remove cylinder head bolts in reverse of tightening sequence. Install locating pins in bolt holes to keep rocker arm shafts from turning. Remove cylinder head.
Inspection
Cylinder head may be machined if necessary. Minimum height is 5.063″ (128.6 mm). Use a .012″ (.30 mm) thicker head gasket if cylinder head is machined.
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BMW 550i, 550i GT, 550xi GT 2005-2010 – SAMPLE

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the BMW 5-Series (E60/E61) 550i, 550i GT, 550xi GT 2005-2010. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for BMW 5-Series (E60/E61) 550i, 550i GT, 550xi GT 2005-2010 is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

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EXCERPT:
SUSPENSION
Steering and wheel alignment – Repair Instructions – 550i
ELECTRONIC CHASSIS ALIGNMENT
00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED THROUGH THE SKIN
Danger of poisoning!
Ingesting oil or absorbing through the skin may cause poisoning!
Possible symptoms are:

Headaches

Dizziness

Stomach aches

Vomiting

Diarrhoea

Cramps/fits

Unconsciousness
Protective measures/rules of conduct:
 Pour oil only into appropriately marked containers
 Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
 Observe country-specific safety regulations
First aid measures:
 Do not induce vomiting.
If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of water and consult a doctor immediately.
If the person affected is unconscious, do not administer anything by mouth, place the person in the recovery position and seek immediate medical attention.
00 RISK OF INJURY IF OIL COMES INTO CONTACT WITH EYES AND SKIN
Danger of injury!
Contact with eyes or skin may result in injury!
…

BMW 545i 2004-2005

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the BMW 545i 2004-2005. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for BMW 545i 2004-2005 is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

EXCERPT:
2004-05 ENGINE Engine Mechanical – Repair Instructions – 545i (4.4L) E60/N62
V/RIBBED BELT W/TENS. DEFLECT ELEMENT
11 28 010 REPLACING ALTERNATOR DRIVE BELT (N62/N62TU)
Special Tools Required:

11 3 340
Necessary Preliminary Tasks:

Remove fan clutch with fan impeller (E65/66). Refer to 11 52 020 REMOVING AND INSTALLING OR REPLACING FAN CLUTCH (N62).
Pretension belt tensioner slowly and carefully with a Torx socket as far as it will go and secure with special tool 11 3 340.
Remove drive belt.
NOTE: For Special Tool identification, see ENGINE- SPECIAL TOOLS – 5-SERIES (E60) .
NOTE: If the drive belt is to be reused: Mark direction of travel and reinstall drive belt in same direction of travel.
IMPORTANT: If contaminated with hydraulic fluid: Replace drive belt.
Fig. 232: Securing Belt Tensioner Using Pin
Put on the drive belt.
Remove special tool 11 3 340.
Installation:
Check that drive belt is correctly positioned on pulleys.
Fig. 233: Identifying Correctly Positioned Drive Belt
NOTE: For Special Tool identification, see AIR CONDITIONING & HEATING – SPECIAL TOOLS – (E60) .
11 28 050 REPLACING A/C COMPRESSOR DRIVE BELT (N62)
Special Tools Required:

64 1 040
Necessary Preliminary Tasks:

Remove alternator drive belt. Refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT
(N62/N62TU).

Remove engine splash guard.
Installation:
If reusing the drive belt, mark the direction of rotation and reinstall in the same direction.
Check drive belt for coolant and oil residues, replace if necessary.
IMPORTANT: If contaminated with hydraulic fluid: Replace drive belt.
Rotate engine at central bolt in direction of engine rotation.
At the same time, pull off drive belt (1) towards front in direction of arrow using a clean cloth (2).
Remove drive belt (1) towards front.
Fig. 234: Removing Drive Belt
Place drive belt (1) in position.
Clamp drive belt (1) with special tool 64 1 040 on belt pulley.
IMPORTANT: If contaminated with hydraulic fluid: Replace drive belt.
NOTE: With Dynamic Drive optional extra, detach bracket from A/C compressor (risk of damage).
…

BMW 540i 1994-2003

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the BMW 540i 1994-2003. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for BMW 540i 1994-2003 is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

EXCERPT:
1997-2003 ENGINE Engine Mechanical 4.4L – Repair Procedures – 540i/E39
V-RIBBED BELT WITH TENSIONER
11 28 010 REPLACING ALTERNATOR DRIVE BELT (M62)
NOTE: If the drive belt is to be subsequently reused:
Mark direction of travel and reinstall drive belt in same direction of travel.
Remove fan clutch with impeller, refer to 11 52 020 REMOVING AND INSTALLING OR REPLACING FAN COUPLING (M62).
Layout of drive belt.
Fig. 313: Layout Of Drive Belt
Slacken screws (1) and relieve tension on belt drive.
NOTE: Release screw (1 and 2) to remove complete belt tensioner.
Remove drive belt.
CAUTION: You must replace the drive belt if it is contaminated with hydraulic fluid.
Installation
Check drive belt for coolant and oil residue and replace if necessary.
Fig. 314: Slackening Screws From Tension On Belt Drive
Installation
Mount drive belt and check that it is correctly positioned on belt pulleys.
Pretension adjustable plate at hexagon head (1) up to end of elongated hole (2) and tighten down screws (3).
CAUTION: Screws (3) up to 9/98 M8 strength class 8.8 tightening torque 22 Nm.
Fig. 315: Aligning Pretension Adjustable Plate At Hexagon Head
Screws (3) from 9/98 with liquid-cooled alternator
M8 strength class 10.9 tightening torque 30 Nm.
11 28 050 REPLACING DRIVE BELT FOR A/C COMPRESSOR (M60 / M62 / M73)
NOTE: If the drive belt is to be reused, mark direction of travel and reinstall drive belt in same direction of rotation.
If necessary, remove splash guard.
Remove alternator drive belt, refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT (M62).
Loosen nuts (2 and 3) and remove compressor drive belt.
Installation
Check drive belt for coolant and oil residue and replace if necessary.
CAUTION: It is essential to replace drive belt if it comes into contact with hydraulic fluid.
…

BMW 535 1985-2016

Complete digital official shop manual contains service, maintenance, and troubleshooting information for the 1985-2016 BMW 535i, 535xi, 535is. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your vehicle like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

535i: 1985-1989 1990-1993 2007-2016
535xi: 2008
535is: 1988

EXCERPT:
ENGINE Engine – Repair Instructions
HOUSING COVER
11 14 005 REPLACING FRONT CRANKSHAFT SEAL
Special tools required:

11 0 371

11 0 372

11 4 370

11 9 221

11 9 222

11 9 224

11 9 231

11 9 232

11 9 233

11 9 234
Necessary preliminary tasks:

Remove VIBRATION DAMPER.
IMPORTANT: Do not release central bolt.
Risk of damage
If the central bolt is released, the sprocket wheels of the timing chain and the oil pump will no longer be non-positively connected to the crankshaft. The camshafts to the crankshaft can warp.
The timing must be ADJUSTED again.
Fig. 66: Identifying Central Bolt
Turn back special tool 11 9 222.
Push special tool 11 9 221 onto crankshaft.
IMPORTANT: When screws are tightened down (special tool 11 9 224 ), crankshaft seal is
pressed inwards approx. 1 mm and thus slackened for subsequent removal.
Insert screws (special tool 11 9 224 ) and tighten down to approx. 20 Nm.
Fig. 67: Identifying Special Tool (11 9 222) (11 9 224) And (11 9 222)
Screw special tool 11 0 371 to 80 Nm into crankshaft seal.
Screw in spindle 11 0 372.
Release crankshaft seal from housing.
Repeat the operation several times if necessary.
Fig. 68: Screwing Special Tool (11 0 371) Into Crankshaft Seal
Carefully saw open crankshaft seal (1) at cutting line (2).
Remove crankshaft seal (1) from special tool 11 0 371.
Fig. 69: Identifying Crankshaft Seal And Cutting Line With Special Tool (11 0 371)
Installation note:
Clean sealing surface (1) and degrease thoroughly in area of housing partition.
Apply a light coat of oil to running surface (2) of crankshaft seal.
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