Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Installation All engines 1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. NOTE: 2.0L engine shown, 2.3L is similar. Inspect and install new intake manifold gaskets if necessary. 2. Install the EGR tube. 3. Position the intake manifold and connect the PCV hose. 4. Connect the KS electrical connector. 2.3L engines 5. NOTE: Be sure to install the bolts in the previously marked locations. NOTE: To ease installation of the intake manifold, lower center mounting bolt, use a 6-inch long, 5/16-inch diameter hose. Install the intake manifold and the seven mounting bolts. 6. NOTE: Lubricate the O-ring with clean engine oil. Install the oil level indicator tube and bolts. 7. Connect the swirl valve electrical connectors and pin-type retainers. 2.0L engines 8. NOTE: Be sure to install the bolts in the previously marked locations. Install the intake manifold and the seven mounting bolts. 9. NOTE: Lubricate the O-ring with clean engine oil. Install the oil level indicator tube and bolt. 10. Connect the swirl control valve electrical connector. 11. If equipped, connect the AIR vacuum supply hose. All engines 12. Install the lower intake bolt. 13. Connect the MAP sensor electrical connector. 14. Connect the IMRC actuator electrical connector. 15. Attach the wiring harness pin-type retainer. 16. Connect the fuel rail pressure and temperature sensor vacuum hose. 17. Connect the power brake booster vacuum tube. Push the vacuum tube into the quick release fitting. 18. Connect the evaporative emissions hose. 19. Connect the IAC valve electrical connector and wiring harness pin-type retainer.

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Installation All vehicles NOTE: CAUTION: Install new D-ring seals on the crankcase-to-head tube. It requires several hours after installation for the D-ring seals to relax back to their original size. If the tube assembly is installed before the D-ring seals have relaxed, damage to the D-ring seals can occur. Late build shown, early build similar. Fig. 10: Installing New D-Ring Seals On Crankcase-To-Head Tube Assembly 1. Install new D-ring seals on the crankcase-to-head tube assemblies. CAUTION: If the fuel injector oil inlet D-shaped O-ring is damaged, a new fuel injector must be installed. Fig. 11: Identifying Fuel Injector O Rings And Electrical Connector Install new O-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and O-ring seals liberally with clean engine oil. CAUTION: Failure to tighten the injector correctly can lead to engine failure. CAUTION: To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.

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Oil Separator – Cold Climate Conditions MODEL NEW E39 5 Series, E46 3 Series, E53 X5, E60 5 Series, E83 X3, E85 Z4 with M54 Engine SITUATION Certain areas of the US experience extremely cold climate conditions during the winter months. A small number of vehicles in the above series listed have experienced problems ranging from leaking or broken valve covers to complete engine failure. CAUSE Moisture accumulating in the engine oil separator, hose to oil dipstick guide tube or the orifice in the dipstick guide tube can freeze. When this occurs, depending on the position of the internal valve, this may either cause high crankcase pressures (stuck closed) resulting in valve cover leakage/breakage or cause an oil hydro-lock condition (stuck open) which could result in engine damage. NEW CORRECTION E39 In case of a customer complaint, replace the crankcase vent valve, crankcase vent hoses and remove and clean the oil dipstick guide tube orifice. E46, E53, E60, E83 and E85 In case of a customer complaint, replace the crankcase vent valve, crankcase vent hoses and dipstick guide tube