Read bmw_torq.pdf text version

Tightening Torques

AZD00-01.frb

20/10/97

00 - 1

General Instructions

Type

Screw

Dimensio n

Unit

00 00 Extract from company standard BMW N 600 02.0

The maximum tightening torques are: Only applicable to shaft screws with metric standard and fine threads acc. to DIN 13, sheet 13 and nuts with height of 0,8 x d acc. to DIN 934 and only for a µ total = 0.125 (screws phosphatized, screws untreated or galvanized. Lubrication condition: unlubricated and also oiled). For cadmium-plated screws or nuts (µ total = 0.08 to 0.09) the tightening torque with screw material at the same level of utilization ca. must be 30% less than shown in the table. The values specified in this table apply to all screw connections conforming to the aforementioned conditions. Not applicable when using a different surface or lubricant condition on the thread, or if the height of the nut differs. Not applicable to necked-down bolts, self-tapping screw connections or to connections between parts made of different materials. Important! Maintaining specified tightening torques is vital for performing repair work to a professional standard. This presupposes that the torque wrenches required for this are subjected to a regular inspection. Approved torque testing equipment is listed in the catalogue of workshop equipment planning documents.

AZD00-02.frb

20/10/97

00 - 2

General Instructions

Type

Screw

Dimensio n

Unit

00 00 M4 and M5 - maximum tightening torques in accordance with BMW N 600 02.0

Applicable range for tightening torques, refer to extract from company standard BMW N 600 02.0 M4 thread M4 8.8 M4 10.9 M4 12.9 M5 thread M5 8.8 M5 10.9 M5 12.9 2.9 4.1 4.9 5.9 8.3 10.0 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD00-03.frb

20/10/97

00 - 3

General Instructions

Type

Screw

Measure

Unit

00 00 M6 and M7 - maximum tightening torques accord. to BMW N 600 02.0

Applicable range for tightening torques, refer to extract from company standard BMW N 600 02.0 M6 thread M6 8.8 M6 10.9 M6 12.9 M7 thread M7 8.8 M7 10.9 M7 12.9 9.9 14.0 16.5 14.8 21.3 25.5 Nm Nm Nm Nm Nm Nm

AZD00-04.frb

20/10/97

00 - 4

General Instructions

Type

Screw

Dimensio n

Unit

00 00 M8 and M8x1 - maximum tightening torques in acc. with BMW N 600 02.0

Applicable range for tightening torques, refer to extract from company standard BMW N 600 02.0 M8 thread M8 8.8 M8 10.9 M8 12.9 M8x1 thread M8x1 8.8 M8x1 10.9 M8x1 12.9 24 34 40 26 36 44 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD00-05.frb

20/10/97

00 - 5

General Instructions

Type

Screw

Dimensio n

Unit

00 00 M10 and M10x1 - maximum tightening torques acc. to BMW N 600 02.0

Applicable range for tightening torques, refer to extract from company standard BMW N 600 02.0 M10 thread M10 8.8 M10 10.9 M10 12.9 M10x1 thread M10x1 8.8 M10x1 10.9 M10x1 12.9 47 66 79 54 75 91 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD00-06.frb

20/10/97

00 - 6

General Instructions

Type

Screw

Dimensio n

Unit

00 00 M12 and M12x1.5 - maximum tightening torques acc. to BMW N 600 02.0

Applicable range for tightening torques, refer to extract from company standard BMW N 600 02.0 M12 thread M12 8.8 M12 10.9 M12 12.9 M12x1.5 thread M12x1.5 8.8 M12x1.5 10.9 M12x1.5 12.9 82 115 140 87 123 147 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD00-07.frb

20/10/97

00 - 7

General Instructions

Type

Screw

Dimensio n

Unit

00 00 M14 and M14x1.5 - maximum tightening torques acc. to BMW N 600 02.0

Applicable range for tightening torques, refer to extract from company standard BMW N 600 02.0 M14 thread M14 8.8 M14 10.9 M14 12.9 M14x1.5 thread M14x1.5 8.8 M14x1.5 10.9 M14x1.5 12.9 130 180 220 143 200 240 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD00-08.frb

20/10/97

00 - 8

General Instructions

Type

Screw

Dimensio n

Unit

00 00 M16 and M16x1.5 - maximum tightening torques acc. to BMW N 600 02.0

Applicable range for tightening torques, refer to extract from company standard BMW N 600 02.0 M16 thread M16 8.8 M16 10.9 M16 12.9 M16x1.5 thread M16x1.5 8.8 M16x1.5 10.9 M16x1.5 12.9 200 280 340 216 303 364 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD00-09.frb

20/10/97

00 - 9

General Instructions

Type

Screw

Dimensio n

Unit

00 00 M18 and M18x1.5 - maximum tightening torques acc. to BMW N 600 02.0

Applicable range for tightening torques, refer to extract from company standard BMW N 600 02.0 M18 thread M18 8.8 M18 10.9 M18 12.9 M18x1.5 thread M18x1.5 8.8 M18x1.5 10.9 M18x1.5 12.9 280 390 470 313 440 527 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD11-1.frb

20/10/97

11 - 1

Engine

Type

Screw

Measure

Unit

11 11 Crankcase

1AZ Main bearing screws Replace, wash and oil main bearing screws M10/M20/M30 M10 60 Nm

M21 S38/S14/M40/M42/M43/M44/M50/ M41/M51/S50/S50 US Torque Torque angle 2AZ Main bearing screws Replace main bearing screws Do not wash off coating on main bearing screw Torque Torque angle M60/1/M60/2/M62 Torque Torque angle on engines with M10 main bearing screws Torque angle on engines with M11 main bearing screws Main bearing screws Replace, wash and oil main bearing screws Torque Torque angle S52/M52 With cast iron engine block M70/S70/M73/M52 With cast aluminium engine block

M10 M10

65

Nm

20 50

Nm °

20 M10 70

Nm °

20 M10 M11 70 100

Nm ° °

20 M10 50

Nm °

AZD11-1.frb

20/10/97

11 - 1

Engine

Type

Screw

Measure

Unit

11 11 Crankcase

1AZ Main bearing screws Replace, wash and oil main bearing screws M10/M20/M30 M10 60 Nm

M21 S38/S14/M40/M42/M43/M44/M50/ M41/M51/S50/S50 US Torque Torque angle 2AZ Main bearing screws Replace main bearing screws Do not wash off coating on main bearing screw Torque Torque angle M60/1/M60/2/M62 Torque Torque angle on engines with M10 main bearing screws Torque angle on engines with M11 main bearing screws Main bearing screws Replace, wash and oil main bearing screws Torque Torque angle S52/M52 With cast iron engine block M70/S70/M73/M52 With cast aluminium engine block

M10 M10

65

Nm

20 50

Nm °

20 M10 70

Nm °

20 M10 M11 70 100

Nm ° °

20 M10 50

Nm °

AZD11-2.frb

20/10/97

11 - 2

Engine

Type

Screw

Measure

Unit

11 11 Crankcase

3AZ Main bearing cap inclined bolts Screws (replace hex and collar screws) and spacer pin Torque Torque angle Threaded support sleeves 4AZ Struts/bracing shell M70/M60/1/M60/2/M62/S70/M73 All All 5AZ 6AZ 7AZ Drain plug for coolant on engine block Main oil duct screw plugs Oil spray nozzle on engine block All All All M10 M8 M14 x 1.5 M16 x 1.5 M8x1 M60/1/M60/2/M62/M70/S70/M73 M8 20 45 10 43 22 25 34 12 Nm ° Nm Nm Nm Nm Nm Nm

AZD11-4.frb

20/10/97

11 - 4

Engine

Type

Screw

Measure

Unit

11 12 Cylinder Head and Cover

2AZ Cylinder head bolts Replace, wash and oil cylinder head bolts. For repair work, only use screws with Torx head torque torque angle torque angle No settling time. No warm-running time. M20 M10 30 90 90 Nm ° °

AZD11-5.frb

20/10/97

11 - 5

Engine

Type

Screw

Measure

Unit

11 12 Cylinder Head and Cover

3AZ Cylinder head bolts Replace, wash and oil cylinder head bolts. torque Torsion angle (screws no. 1 - 10) Torsion angle (screws no. 11 - 14) warm-running time torque angle 4AZ Cylinder head bolts Replace, wash and oil cylinder head bolts. torque settling time torque warm-running time torque angle M30 M21

50 90 73 15 90

Nm ° ° min °

60 20 80 25 35

Nm min Nm min °

AZD11-6.frb

20/10/97

11 - 6

Engine

Type

Screw

Measure

Unit

11 12 Cylinder head with cover

5AZ Cylinder head bolts Replace, wash and oil cylinder head bolts Torque Loosen all bolts 1/2 turn Torque Torque angle Torque angle warm-running time Torque angle 6AZ Cylinder head bolts Replace, wash and oil cylinder head bolts M40/M42/M43/M44/M50/S50 US/ S52/M52 With cast iron engine block M10 50 90 90 25 90 Nm ° ° min ° M51/M41 M11

80

Nm

Torque Torque angle Torque angle Cylinder head bolts Fit new cylinder head bolts Do not wash away coating on cylinder head screws Torque Torque angle Torque angle M52 With cast aluminium engine block M10

30 90 90

Nm ° °

40 90 90

Nm ° °

AZD11-6A.frb

20/10/97

11 - 7

Engine

Type

Screw

Measure

Unit

11 12 Cylinder head with cover

6AZ Cylinder head bolts Replace, wash and oil cylinder head bolts Torque Torque angle Torque angle S50 M11

30 90 90

Nm ° °

AZD11-7.frb

20/10/97

11 - 8

Engine

Type

Screw

Measure

Unit

11 12 Cylinder head with cover

7AZ Cylinder head bolts Fit new cylinder head bolts Do not wash away coating on cylinder head screws For repair work, only use screws with Torx head Torque Torque angle Torque angle 8AZ Cylinder head bolts Fit new cylinder head bolts Do not wash away coating on cylinder head screws Torque Torque angle Torque angle M60/1/M60/2/M62 M10 M70/S70/M73 M10

30 60 60

Nm ° °

30 80 80

Nm ° °

AZD11-8.frb

20/10/97

11 - 9

Engine

Type

Screw

Measure

Unit

11 12 Cylinder Head and Cover

9AZ Cylinder head bolts Replace, wash and oil cylinder head bolts. torque torque settling time torque 10AZ Cylinder head bolts Replace, wash and oil cylinder head bolts. torque torque angle torque angle S38 B36/S38 B38 M12 S14/S38 B35 M12

50 80 15 100

Nm Nm min Nm

20 60 70

Nm ° °

AZD11-9.frb

20/10/97

11 - 10 Engine

11 12 Cylinder Head and Cover

11AZ Cylinder head cover All All M21 12AZ 13AZ Oil trap to cylinder head cover Timing case to cylinder head M21 All All

Type

Screw

Measure

Unit

M6 M7 M8 M8 M7 M8

10 15 15 17 15 20

Nm Nm Nm Nm Nm Nm

AZD11-10.frb

20/10/97

11 - 11 Engine

11 13 Oil Pan

1AZ Oil drain plug All All 2AZ Oil pan on engine block All All

Type

Screw

Measure

Unit

M12 x 1.5 M22 x 1.5 M6 8.8 M6 10.9

25 60 10 12

Nm Nm Nm Nm

AZD11-11.frb

20/10/97

11 - 12 Engine

11 14 Case covers

1AZ Timing case and top and bottom timing case cover All All All 2AZ Front/rear end cover to crankcase All All 3AZ 4AZ Bolts on timing case cover Sealing plug or connector on timing case cover M51/M41 M51/M41

Type

Screw

Measure

Unit

M6 M8 M10 M6 M8 M42x1.5 M20x1.5

10 22 47 10 22 65 30

Nm Nm Nm Nm Nm Nm Nm

AZD11-11A.frb

20/10/97

11 - 13 Engine

11 21 Crankshaft and Bearings

1AZ Increment wheel on crankshaft All

Type

Screw

Dimensio n

Unit

M5 10.9

13

Nm (ft. lbs.)

AZD11-12.frb

20/10/97

11 - 14 Engine

11 22 Flywheel

1AZ Flywheel to crankshaft Do not install with screw retaining compound. Bolts are a component part of the flywheel. Screw threads oiled. New micro-encapsulated screws

Type

Screw

Measure

Unit

M60/1/M60/2/M62 Manual Transmission M40/M42/M43/M44/ M51 Automatic/M52 Automatic All others

105

Nm

120

Nm

New micro-encapsulated screws

105

Nm

AZD11-13.frb

20/10/97

11 - 15 Engine

11 23 Vibration Damper

1AZ 2AZ Vee belt pulley on crankshaft Vibration damper hub on crankshaft Replace screws M10

Type

Screw

Measure

Unit

190 M18 x 1.5 410

Nm Nm

M20/M21/M50/M52/S50 US/S52

M30/S14/S38 B 35 M41/M51/M60/1/M60/2/M62 Torque Torque angle Torque angle Torque angle M70/S70/M73 Torque Torque angle Torque angle S38 B36 Torque Unfasten screw one half turn Torque Torque angle Torque angle Torque angle

M24 x 1.5 M18 x 1.5

440

Nm

100 60 60 30 M18 x 1.5 100 60 60 M20 x 1.5 150

Nm ° ° °

Nm ° °

Nm

60 60 60 30

Nm ° ° °

AZD11-13A.frb

20/10/97

11 - 16 Engine

11 23 Vibration Damper

2AZ Vibration damper hub on crankshaft Replace screws S38 B38

Type

Screw

Dimensio n

Unit

M12x1.5

S50 torque torque angle torque angle

M12x1.5 60 50 50 Nm ° °

AZD11-14.frb

20/10/97

11 - 17 Engine

11 23 Vibration Damper

3AZ Vee belt pulley / vibration damper on hub S38 B36 S38 B 38 All others 4AZ Pulley to vibration damper S38 B 35 S50 5AZ Sprocket with hub or hub to crankshaft Replace screw M40

Type

Screw

Measure

Unit

M8 10.9 M8 10.9 M8 M8 8.8 M8 8.8 M16 x 1.5

34 34 22 22 22 310

Nm Nm Nm Nm Nm Nm

M42/M43/M44

M16 x 1.5

330

Nm

AZD11-15.frb

20/10/97

11 - 18 Engine

11 24 Connecting Rods and Bearings

1AZ Connecting rod bolts Replace, wash and oil conrod bolts M10/M30

Type

Screw

Measure

Unit

55

Nm

M20/M21/M40/M41/M42/M43/ M44/M50/M51/M52/S52/S50 US/ M70/S70/M73 Application torque Torque Torque angle M60/1/M60/2/M62 Application torque Torque Torque angle 5 20 80 Nm Nm ° 5 20 70 Nm Nm °

AZD11-16.frb

20/10/97

11 - 19 Engine

11 24 Connecting Rods and Bearings

1AZ Connecting rod bolts Replace, wash and oil conrod bolts S14

Type

Screw

Measure

Unit

55

Nm

S38 Application torque Torque Torque angle S50 Application torque Torque Torque angle 5 20 65 Nm Nm ° 5 30 60 Nm Nm °

AZD11-17.frb

20/10/97

11 - 20 Engine

11 28 V-ribbed belt with tension and deflection element

1AZ Idler lever to alternator bracket Replace screw Screw plug for bearing pin M43

Type

Screw

Measure

Unit

M10 10.9

90

Nm

2AZ

M51/M41

20

Nm

AZD11-18.frb

20/10/97

11 - 21 Engine

11 31 Camshaft

1AZ Camshaft bearing cap All All All 2AZ 3AZ Sprocket to camshaft Sprocket to camshaft flange

Type

Screw

Measure

Unit

M6 M7 M8 M10 M6 M6 M7

10 15 20 65 15 10

Nm Nm Nm Nm Nm Nm

M20/M21/M40 M60/1/M60/2/M62 All others M50/M52/S52/S50 US/M50 VANOS

Application torque Torque All others 4AZ Sprocket to camshaft Torque Torque angle 5AZ Splined shaft to intake camshaft Torque Torque angle M52/S52/S50 US/M50 VANOS M14 x 1.5 M51/M41 M7

5 22 15

Nm Nm Nm

20 35

Nm °

40 60

Nm °

AZD11-19.frb

20/10/97

11 - 22 Engine

11 31 Camshaft

6AZ 7AZ Flange to camshaft Plug for chain tensioner M30 M50/S50 US All others 8AZ Cylinder for chain tensioner plunger

Type

Screw

Measure

Unit

145 M22 x 1.5 M22 x 1.5 M26 x 1.5 M26 x 1.5 M6 M6 M7 M6 50 40 70 50 13 13 15 10

Nm Nm Nm Nm Nm Nm Nm Nm Nm

M50/M52/S52/S50 US All others

9AZ 10AZ 11AZ

Bearing flange on engine block Reversing rail on engine block Screw-in pin on camshaft Nut on screw-in pin

M60/1/M60/2 M62 All All

AZD11-20.frb

20/10/97

11 - 23 Engine

11 33 Rocker Arms/Drag Arms and Bearings

1AZ Clamping bolt in rocker arm Clamping bolt in drag arm

Type

Screw

Measure

Unit

M10/M20/M30 M21

M6 M6

10 8

Nm Nm

AZD11-21.frb

20/10/97

11 - 24 Engine

11 35 Intermediate Shaft

1AZ Toothed belt pulley to intermediate M20/M21

Type

Screw

Measure

Unit

M10

60

Nm

AZD11-22.frb

20/10/97

11 - 25 Engine

11 36 Variable Camshaft Control

1AZ 2AZ 3AZ 4AZ 5AZ 6AZ 7AZ 8AZ 9AZ 10AZ 4/2 way directional valve/solenoid valve on VANOS housing Banjo bolt to VANOS controller Plug to VANOS adjusting unit Plug to hydraulic plunger Hydr. line for VANOS on oil filter aggregate carrier Collar nut on toothed shaft (nut secured with Loctite) Cover on VANOS control unit (hydraulic pistons, intake side) Filter screw on VANOS adjusting unit Pressure line on pressure accumulator and VANOS adjustment unit Cover for solenoid valve on VANOS control unit

Type

Screw

Measure

Unit

M52/S52/S50 US/M50 VANOS M52/S52/S50 US/M50 VANOS M52/S52/S50 US/M50 VANOS M52/S52/S50 US/M50 VANOS M52/S52/S50 US/M50 VANOS S50 S50 S50 S50 S50 B 30 S50 B 32 M6 M5 M10x1 M12x1 M5 8.8 M5 10.9 M6 10.9 M14 x 1.5 M22 x 1.5 M36x1

30 32 50 60 32 9 5 12 20 6 8 13

Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm

11AZ

Cover on VANOS control unit (hydraulic pistons, exhaust side)

S50 B 32

AZD11-23.frb

20/10/97

11 - 26 Engine

11 41 Oil Pump with Strainer and Drive

1AZ Plug for pressure relief valve M10/M30 M20 2AZ 3AZ 4AZ Oil pump to crankcase Oil pump cover Sprocket to oil pump All All All All All

Type

Screw

Dimensio n

Unit

40 30 M8 M6 M6 M10 M10x1 22 10 10 47 25

Nm Nm Nm Nm Nm Nm Nm

AZD11-24.frb

20/10/97

11 - 27 Engine

11 42 Oil Filter and Pipes

1AZ Oil filter (one-way cartridge) (Tightening torque by hand in acc. with specification on spin-on oil filter) Full flow oil filter (cover) All

Type

Screw

Measure

Unit

Nm

2AZ

All All All

M8 M10 M12

22 33 33 25

Nm Nm Nm Nm Nm Nm

Screwed-on cover 3AZ Oil filter housing and lines on crankcase

All All All M8 M20 x 1.5

22 40

AZD11-25.frb

20/10/97

11 - 28 Engine

11 42 Oil Filter and Pipes

4AZ Oil filter drain plug Hollow bolt Solid aluminium screw Full length screw in threaded insert 5AZ 6AZ 7AZ Oil drain line on oil filter and upper section of oil pan (banjo bolt) Oil line to bearing points and camshaft lubrication Oil line for camshaft lubrication on cylinder head Hollow bolt All All M21/S38 M21 M21

Type

Screw

Measure

Unit

20 10 23 30 M6 10

Nm Nm Nm Nm Nm

M60/1/M60/2/M62/M70/S70/M73 All

M8x1 M5

10 5

Nm Nm

AZD11-26.frb

20/10/97

11 - 29 Engine

11 42 Oil Filter and Pipes

8AZ 9AZ 10AZ Oil cooler oil pipes to oil filter housing Oil pipes to turbocharger Oil lines from turbocharger to engine block Hollow bolt Oil supply pipe to turbocharger Hollow bolt Coupling nut All All All All All

Type

Screw

Measure

Unit

M8 M8 M16 x 1.5

22 22 40

Nm Nm Nm

11AZ

25 30

Nm Nm

AZD11-27.frb

20/10/97

11 - 30 Engine

11 51 Water Pump and Drive

1AZ Water pump to crankcase All All

Type

Screw

Measure

Unit

M8 M6

22 10

Nm Nm

AZD11-28.frb

20/10/97

11 - 31 Engine

11 52 Fan

1AZ Fan clutch on water pump Coupling nut (left-hand threads) All

Type

Screw

Measure

Unit

40

Nm

AZD11-29.frb

20/10/97

11 - 32 Engine

11 53 Thermostat and Connections

1AZ 2AZ Thermostat housing Bleeder screw All All

Type

Screw

Measure

Unit

M6 M8

10 8

Nm Nm

AZD11-30.frb

20/10/97

11 - 33 Engine

11 61 Intake manifold

1AZ Intake manifold on cylinder head All All All 2AZ Soundproofing hood to holder

Type

Screw

Measure

Unit

M8 M7 M6 M6

22 15 10 8

Nm Nm Nm Nm

M60/1/M60/2/M62

AZD11-31.frb

20/10/97

11 - 34 Engine

11 62 Exhaust manifold

1AZ Exhaust manifold to cylinder head Screw connections on exhaust with Molykote HSC compound coat All

Type

Screw

Measure

Unit

M6

10

Nm

M50/M52/S52/S50 US All others Upper row of staybolts installed with bolt cement Retorque after 2000 km Loosen bolt first All M21

M7 M7 M8 M8

20 15 22 12

Nm Nm Nm Nm

AZD11-32.frb

20/10/97

11 - 35 Engine

11 62 Exhaust manifold

2AZ Exhaust manifold to cylinder head (Apply Molykote HSC paste to exhaust nuts and M30 Turbo bolts) When mounting on new cylinder head or with new studs Subsequent mounting Retorque after 2000 km Loosen bolt first Install studs with Molykote HSC Protrusion from head: Short studs Protrusion from head: Long studs

Type

Screw

Measure

Unit

M10

28 15 15

Nm Nm Nm

88 + 1.0 98 + 0.5

mm mm

AZD11-33.frb

20/10/97

11 - 36 Engine

11 65 Turbocharger and Control

1AZ Turbocharger to exhaust manifold M21

Type

Screw

Measure

Unit

M10

25 45

Nm Nm Nm Nm Nm Nm Nm Nm

M30/M51/M41 2AZ 3AZ 4AZ 5AZ 6AZ 7AZ Bypass valve to flow section Ring nut to exhaust manifold Screws to bypass valve Charge tract to exhaust manifold Oil return flange to turbocharger Oil supply for turbocharger and engine block Hollow bolt Threaded plug to oil return Control pipe to bypass valve/turbocharger M30 M30 M30 M30 M30 M51/M41 M6 M8 M8 M8

25 220 10 22 22 25

8AZ 9AZ

M30 M30

M16

45 30

Nm Nm

AZD11-34.frb

20/10/97

11 - 37 Engine

11 66 Vacuum pump

1AZ Vacuum pump on cylinder head All M51/M41 microencapsulated M51/M41

Type

Screw

Measure

Unit

M6 M8 M9

10 22 22

Nm Nm Nm

AZD11-34A.frb

20/10/97

11 - 38 Engine

11 72 Air pump, lines and control valves

1AZ 2AZ Cap nut on air intake tube Compression screw Lock nut M60/1/M60/2 M60/1/M60/2 M60/1/M60/2

Type

Screw

Dimensio n

Unit

30 M6 M6 5 5

Nm Nm Nm

AZD11-35.frb

20/10/97

11 - 39 Engine

11 78 Emissions-control, Lambda oxygen sensor

1AZ Oxygen sensor and oxygen monitor sensor All

Type

Screw

Measure

Unit

55

Nm

AZD11-36.frb

20/10/97

11 - 40 Engine

11 81 Engine Suspension

1AZ Rubber mount to front axle carrier All All 2AZ Rubber mount to engine console All All 3AZ Engine console to engine All All

Type

Screw

Measure

Unit

M8 M10 M8 M10 M8 M10

22 47 22 47 22 47

Nm Nm Nm Nm Nm Nm

AZD12-1.frb

20/10/97

12 - 1

Engine Electrical Equipment

Type

Screw

Measure

Unit

12 11 Distributor

1AZ Distributor M20 M10/M30 2AZ 3AZ Distributor rotor to adapter with DME High-tension distributor cap All All 22 10 2.8 4 Nm Nm Nm Nm

AZD12-2.frb

20/10/97

12 - 2

Engine Electrical System

Type

Screw

Measure

Unit

12 12 Spark plugs

1AZ Spark plugs (ungreased) All All M12x1.25 M14x1.25 23 ± 3 30 ± 3 Nm Nm

AZD12-2A.frb

20/10/97

12 - 3

Engine Electrical System

Type

Screw

Dimensio n

Unit

12 13 Ignition Coil

1AZ Primary connections Terminal 1 Terminal 15 2AZ 3AZ Ignition coil on wheel arch / end wall Ignition coil on wheel arch All All M42/M43/M44 M40 3.0 4.5 5 16 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD12-3.frb

20/10/97

12 - 4

Engine Electrical System

Type

Screw

Dimensio n

Unit

12 14 Electronic Shift Units or Control Units

1AZ 2AZ TCI control unit Knock sensor All E23 All 3AZ 4AZ 5AZ 6AZ Speed and reference mark senders Cover on control unit box Angle impulse sensor on cylinder head Crankshaft sensor on timing case cover Crankshaft sensor on cylinder crankcase All with DME E38 M52 M52 2.5 13 20 7 4.4 5.0 5.0 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD12-4.frb

20/10/97

12 - 5

Engine Electrical Equipment

Type

Screw

Measure

Unit

12 21 Preheating Relay

1AZ 2AZ Terminal 30 wire to glow plug relay 80 A fuse on glow plug relay M41/M51 M41/M51 4 2 Nm Nm

AZD12-4A.frb

20/10/97

12 - 6

Engine Electrical Equipment

Type

Screw

Value

Unit

12 23 Glow Plugs

1AZ 2AZ 3AZ Glow plug Glow plug 4" Wire to glow plug M21 M21/M41/M51 M21/M41/M51 25 20 4 Nm Nm Nm

AZD12-5.frb

20/10/97

12 - 7

Engine Electrical System

Type

Screw

Dimensio n

Unit

12 31 Alternator with Drive and Mounting Parts

1AZ Wires to alternator Kl. D+ M10/M20 All others Kl. B+ S38 B 38 All others 2AZ 3AZ 4AZ 5AZ 6AZ Pulley Pulley (ribbed drive belt) Rear holder Fillister head screw for wire holder Alternator on bearing block All All All All M40/M42/M43/M44 M8 M6 5 7 8 13 45 60 3.5 3.5 43 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD12-5A.frb

20/10/97

12 - 8

Engine Electrical Equipment

Type

Screw

Value

Unit

12 32 Governor

1AZ Regulator switch All All M4 M5 2 4 Nm Nm

AZD12-6.frb

20/10/97

12 - 9

Engine electrics

Type

Screw

Dimensio n

Unit

12 41 Starter and Mounting Parts

1AZ 2AZ 3AZ 4AZ Starter mount Support to starter Support to crankcase Electrical leads to starter Terminal 30h Terminal 50 Terminal 30 5AZ Bolt connection, pole tube All All All All M5 M6 M8 M6 5 6 12 6 Nm Nm Nm Nm All All All M5 50 5 47 Nm Nm Nm

AZD12-7.frb

20/10/97

12 - 10 Engine Electrical Equipment

12 42 Wires to starter

1AZ 2AZ Battery positive connection point in power distributor Wiring harness on distributor

Type

Screw

Measure

Unit

E32/E34/E31/E36 E36 M41

M8 M8

20 10

Nm Nm

AZD12-7A.frb

20/10/97

12 - 11 Engine Electrical Equipment

12 52 Plug Connectors, Terminals

1AZ 2AZ Holder for modules Ground connections Flange nut Cover on heating splash wall E36 E36

Type

Screw

Value

Unit

M6

9 16

Nm Nm

3AZ

E36

1.1

Nm

AZD12-7AA.frb

20/10/97

12 - 12 Engine Electrical Equipment

12 51 Engine wiring harness

1AZ 2AZ Wiring harness on electrical cutout device Wiring harness connection on distributor M51/M41 E36 M41

Type

Screw

Measure

Unit

M5 M8

2.5 10

Nm Nm

AZD12-8.frb

20/10/97

12 - 13 Engine Electrical System

12 61 Oil pressure, oil temperature, oil level display

1AZ Oil-pressure switch/oil-temperature switch Note: Oil and screw in S14/S50/S38

Type

Screw

Measure

Unit

20

Nm

M60/M62/M73 All others

27 35

Nm Nm

AZD12-9.frb

20/10/97

12 - 14 Engine electrics

12 62 Coolant Temperature

1AZ Temperature sensor to water flange (glow time/coolant temperature gage) M21 M51 2AZ 3AZ Temperature switch (5.5 °C / 17 °C) to fuel filter/cylinder head Coolant temperature sensor (2-pin plug-in connection) M21 S38/S50 All others 4AZ 5AZ 6AZ 7AZ Remote thermometer sensor (2-pin plug-in connection) Remote thermometer sensor on coolant flange Temperature sensor - air Temperature sensor - oil All others S50 S38/S50 S38/S50

Type

Screw

Dimensio n

Unit

18 13 18 13 20 20 18 13 13

Nm Nm Nm Nm Nm Nm Nm Nm Nm

AZD12-10.frb

20/10/97

12 - 15 Engine Electrical Equipment

12 63 Switches and Relays

1AZ Temperature switch for electronic box E32/E34/E31

Type

Screw

Measure

Unit

15

Nm

AZD12-10A.frb

20/10/97

12 - 16 Engine Electrical System

12 72 Senders for Control Unit

1AZ 2AZ Lever to pedal value sender Pedal value sender to pedal console

Type

Screw

Measure

Unit

E32/E34/E31/E36 E32/E34/E31

9 5

Nm Nm

AZD12-11.frb

20/10/97

12 - 17 Engine Electrical System

12 90 Control unit housing

1AZ 2AZ 3AZ 4AZ Assembly of upper and lower sections Center section to body Control unit holder in E box Control unit box cover E32/E34/E36 E32/E34 E36 E38/E39

Type

Screw

Dimensio n

Unit

5 3 5 4.4

Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD13-1.frb

20/10/97

13 - 1

Fuel delivery and metering system

Type

Screw

Measure

Unit

13 11 Carburetor

1AZ 2AZ 3AZ 4AZ 5AZ 6AZ 7AZ 8AZ 9AZ Carburetor to intake manifold Carburetor to insulating flange Insulating flange to intake manifold Idling shutoof valve; max. Flow valve; max. Throttle valve assembly to float housing; max. Throttle valve neck to intake manifold Throttle valve control to carburetor; max. Warm-up regulator to engine M10/M20/M30 M10/M20/M30 M10/M20/M30 M10/M20/M30 M10/M20/M30 M10/M20/M30 M10/M20/M30 2BE M10/M20/M30 10 10 10 5 28 9 10 3 23 Nm Nm Nm Nm Nm Nm Nm Nm Nm

AZD13-2.frb

20/10/97

13 - 2

Fuel delivery and metering system

Type

Screw

Measure

Unit

13 31 Fuel Pump with Drive and Pipes

1AZ 2AZ 3AZ 4AZ 5AZ Fuel pump to engine Fuel pipe coupling bolt Fuel pipe coupling bolt Fuel pipe to pressure regulator Return pipe connector to pressure regulator All All with K-Jetr. All with K-Jetr. All with L-Jetr. All with L-Jetr. M8 M12 12 9 20 30 27 Nm Nm Nm Nm Nm

AZD13-3.frb

20/10/97

13 - 3

Fuel delivery and metering system

Type

Screw

Measure

Unit

13 32 Fuel filter

1AZ Fuel line to filter housing and injection pump Coupling nut Adapter Hollow bolt 2AZ Fuel filter to holder M21/M51/M41 M21/M51/M41 M21/M51/M41 M51/M41 M14 x 1.5 M12 x 1.5 M14 x 1.5 M8 14 9 14 22 Nm Nm Nm Nm

AZD13-4.frb

20/10/97

13 - 4

Fuel delivery and metering system

Type

Screw

Measure

Unit

13 51 Injection Pump Control receptacle

1AZ 2AZ 3AZ 4AZ 5AZ 6AZ 7AZ Plug for high pressure section of injection pump Distributor injection pump to holder Electric shutoff to injection pump Electric cold start valve to injection pump Coupling bolt (OUT) to injection pump (fuel return) Pressure valve holder to injection pump Expansion element housing (temperature dependent idling speed boost) to injection pump Distributor injection pump to flange and console Electr. line on fuel cutout device M21/M51/M41 M21/M51/M41 M21/M51/M41 M21 M21/M51/M41 M21/M51 M21 25 25 20 ± 5 20 25 45 18 Nm Nm Nm Nm Nm Nm Nm

8AZ 9AZ

M21/M51/M41 M51/M41

22 2.5

Nm Nm

AZD13-5.frb

20/10/97

13 - 5

Fuel delivery and metering system

Type

Screw

Measure

Unit

13 52 Injection Pump Drive

1AZ 2AZ 3AZ Chain sprocket to injection pump Toothed belt pulley to injection pump Chain tensioner M21 M51/M41 M51/M41 47 50 15 Nm Nm Nm

AZD13-6.frb

20/10/97

13 - 6

Fuel metering and regulation system

Type

Screw

Dimensio n

Unit

13 53 Fuel Injection Nozzles and Pipes

1AZ 2AZ Injection nozzle combination (assembly) Injection nozzle combination to cylinder head M21/M51 M21 M51/M41 3AZ 4AZ Injection pipe (coupling nut) to injection pump and nozzle combination Feed line on injection panel M21/M51/M41 M43/M44 80 40 65 20 20 Nm Nm Nm Nm Nm

AZD13-7.frb

20/10/97

13 - 7

Fuel System

Type

Screw

Measure

Unit

13 62 Senders for Control Unit

1AZ 2AZ Temperature time switch Coolant temperature sensor M21/M51 M60/1/M60/2/M21/M51 All others 3AZ 4AZ 5AZ 6AZ Temperature switch Temperature sensor - air Charge pressure sensor on holder Twin temperature sensor (4-pin plug-in connection) All All M51/M41 M41/M43/M44/S50/S52/M52/M62/ M73 M51 18 18 13 28 13 4 13 Nm Nm Nm Nm Nm Nm Nm

7AZ

Air-mass sensor on lower section of air filter housing

3.5

Nm

AZD13-8.frb

20/10/97

13 - 8

Fuel delivery and metering system

Type

Screw

Measure

Unit

13 64 Fuel Injectors

1AZ 2AZ Fuel injector to intake manifold Coupling nut on fuel injector All All with K-Jetr. M6 10 25 Nm Nm

AZD13-9.frb

20/10/97

13 - 9

Fuel System

Type

Screw

Measure

Unit

13 71 Air intake silencer

1AZ Air intake silencer on cylinder head cover M41/M51 M6 6 Nm

AZD13-10.frb

20/10/97

13 - 10 Fuel System

13 80 Gas-powered units

1AZ Screw plug on low-pressure regulator 316g/518g

Type

Screw

Measure

Unit

3

Nm

AZD13-11.frb

20/10/97

13 - 11 Fuel System

13 81 Air intake valves, low-pressure and vacuum hoses

1AZ Air intake line on low-pressure unit 316g/518g

Type

Screw

Measure

Unit

22

Nm

AZD13-12.frb

20/10/97

13 - 12 Fuel System

13 82 Mixture and metering system, low-pressure reducer

1AZ MAP sensor on holder 316g/518g

Type

Screw

Measure

Unit

3.5

Nm

AZD13-13.frb

20/10/97

13 - 13 Fuel System

13 83 Gas tank with attachment

1AZ 2AZ 3AZ 4AZ Support frame on body Gas density sensor on non-return cock of gas tank Holder of filler connection on body Holder for filler connections on body 316g/518g 316g/518g 316g 518g

Type

Screw

Measure

Unit

45 35 5 3

Nm Nm Nm Nm

AZD16-1.frb

20/10/97

16 - 1

Fuel tank and fuel lines

Type

Screw

Dimensio n

Unit

16 11 Fuel Tank and Mounting Parts

1AZ Fuel tank to body Screw nut nut Retaining strap Retaining strap 2AZ 3AZ Connecting pipe to fuel tank Heat shield to fuel tank E39 E30 E30 E24 E31 4AZ Drain plug on fuel tank All M8 All M8 23 Nm (ft. lbs.)

E30 E24

M8 M8

25 45 8 23 25 8.5 1.0 3 25

Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD16-2.frb

20/10/97

16 - 2

Fuel tank and fuel lines

Type

Screw

Measure

Unit

16 12 Fuel Supply

1AZ 2AZ 3AZ 4AZ 5AZ 6AZ 7AZ Pump assembly to metal-bonded mount Holder to fuel pump or fuel reservoir Electric connections on fuel pump Electric connections on fuel pump Electric connections on fuel pump Plastic nut on cover for fuel pipes Hose clamps 10 - 16 mm dia. All with fuel injection All with fuel injection All with fuel injection All with fuel injection All with fuel injection E30 All M4 M5 6.5 6.5 2 1.2 1.6 2 2 Nm Nm Nm Nm Nm Nm Nm

AZD16-3.frb

20/10/97

16 - 3

Fuel tank and fuel lines

Type

Screw

Dimensio n

Unit

16 13 Fuel Vapor Venting

1AZ Fuel vapor venting tank to body E24 E30 E39 3 4.5 4.0 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD16-4.frb

20/10/97

16 - 4

Fuel Tank and Fuel Lines

Type

Screw

Measure

Unit

16 14 Fuel Pump

1AZ Fuel level sender to fuel intake All with transfer pump in tank E32 2AZ End ring for fuel tank (fuel level sender/pump) Plastic sealing ring, 26.5 mm high Plastic sealing ring, 31.5 mm high (new) Torque angle Torque Metal sealing ring 3AZ Intank pump with fill level sensor on tank (tighten nuts crosswise) E39 E38 M6 E34/E31 E36/E34/E31 720 55 35 6.5 ° Nm Nm Nm 40 Nm 2 8 Nm Nm

AZD17-1.frb

20/10/97

17 - 1

Radiator

Type

Screw

Measure

Unit

17 00 Coolant

1AZ 2AZ 3AZ Cooland hoses 32 ... 48 mm dia. Bleeder screw (8 mm wrench size) on thermostat housing Level switch (30 mm wrench size) to coolant expansion tank All All All 2.5 8 3 Nm Nm Nm

AZD17-2.frb

20/10/97

17 - 2

Radiator

Type

Screw

Measure

Unit

17 11 Radiator and Mounting Parts

1AZ Radiator to body self-tapping screw All All 2AZ 3AZ 4AZ Drain plug on radiator Temperature switch to radiator (91°C / 99°C) max. Expansion tank to body All All All B6.3 M6 9 10 2.5 15 9 Nm Nm Nm Nm Nm

AZD17-3.frb

20/10/97

17 - 3

Radiator

Type

Screw

Measure

Unit

17 21 Engine Oil Cooler

1AZ Engine oil cooler to body Oil cooler vapor extraction guide to trim panel All E36 M3 B4.8 14 4 Nm Nm

AZD17-4.frb

20/10/97

17 - 4

Radiator

Type

Screw

Measure

Unit

17 22 Oil Cooler Pipes

1AZ 2AZ 3AZ 4AZ Pipes to engine oil cooler Pipes to oil filter head Holder on oil cooler pipes Holder for oil cooler pipes to alternator All E36 M3 All E36 M3 M6 28 25 6 10 Nm Nm Nm Nm

AZD17-5.frb

20/10/97

17 - 5

Radiator

Type

Screw

Measure

Unit

17 22 Oil Cooler Pipes

5AZ Cap nut on transmission oil cooler (on radiator) and on transmission All 5HP30 6AZ Oil lines on transmission Hollow bolt 7AZ Oil lines on transmission oil cooler Hollow bolt 8AZ Screw-in fitting on transmission All A5S 300J All All M14 x 1.5 M14x1.5 und M16x1.5 M16 x 1.5 37 28 27 37 Nm Nm Nm Nm M18x1.5 M22x1.5 20 28 Nm Nm

9AZ 10AZ 11AZ 12AZ

Oil hose on oil pipe Oil pipe bracket on radiator Oil pipe bracket on body Oil cooler on transmission

E23 E23 E23 5HP30

28 2 6.5 10

Nm Nm Nm Nm

AZD18-1.frb

20/10/97

18 - 1

Exhaust system

Type

Screw

Dimensio n

Unit

18 00 Exhaust Assembly

1AZ Exhaust pipe to exhaust manifold or turbocharger Version with compression spring: M30/M70 Evenly tighten the compression springs with nuts on the block, then loosen by 1.5 revolutions Preload compression springs with nuts to 27 ± 1 mm Version without compression springs 2AZ 3AZ 4AZ Exhaust pipe to flow section Clamp for final muffler Catalytic converter on silencer Version with compression spring: Evenly preload compression springs with nuts to 30 mm E36 M42 M51 S50 E23 All M8 M10 30 25 15 Nm Nm Nm 10 Nm

AZD21-11-01.frb

20/10/97

21 - 1

Clutch

Type

Screw

Measure

Unit

21 11 Bell housing

1AZ Clutch housing to crankcase All All All M8 M10 M12 27 51 86 Nm Nm Nm

AZD21-21-01.frb

20/10/97

21 - 2

Clutch

Type

Screw

Measure

Unit

21 21 Clutch disc and drive plate

1AZ Clutch to flywheel All All Replace bolt and taper sleeve. S14/S38 B36 M8 8.8 M8 10.9 M8 10.9 24 34 34 Nm Nm Nm

AZD21-52-01.frb

20/10/97

21 - 3

Clutch

Type

Screw

Measure

Unit

21 52 Clutch operation (hydraulic)

1AZ 2AZ 3AZ 4AZ 5AZ Coupling bolts for hydraulic pipes Master cylinder to console Master cylinder setscrew Master cylinder to pedal assembly Slave cylinder to clutch housing or transmission case All All All All All 17 22 22 10 22 Nm Nm Nm Nm Nm

AZD23-00-01.frb

20/10/97

23 - 1

Manual Transmission

Type

Screw

Measure

Unit

23 00 Transmission in general

1AZ Transmission to engine Hex screws All All All Torx bolts All All All M8 M10 M12 M8 M10 M12 25 49 74 22 43 72 Nm Nm Nm Nm Nm Nm

AZD23-2.frb

20/10/97

23 - 2

Manual transmission

Type

Screw

Measure

Unit

23 00 Transmission Assembly

2AZ 3AZ 4AZ Transmission to clutch housing Reinforcement plate to transmission Oil drain plug/filler plug All All All S 6 S 560 G M12 M8 76 23 50 52 Nm Nm Nm Nm

AZD23-3.frb

20/10/97

23 - 3

Manual transmission

Type

Screw

Measure

Unit

23 11 Case and Covers

1AZ 2AZ Transmission case rear/front sections Cover with guide tube/transmission case All All All All 3AZ 4AZ 5AZ Bearing cap/sealing flange Reverse gear shaft on intermediate housing Retaining plate for reverse gear shaft on intermediate housing All All All M8x22 M8x30 M6 22 18 25 10 10.5 49 25 Nm Nm Nm Nm Nm Nm Nm

AZD23-4.frb

20/10/97

23 - 4

Manual Transmission

Type

Screw

Measure

Unit

23 11 Case and Cover

6AZ Reverse gear shaft to case All S 5 D 310 Z All 7AZ 8AZ 9AZ 10AZ Support for reverse gear shaft Bearing bracket on rear section of case Mounting tabs for sealing cover Bearing on countershaft 240/260 240/260/265/280 280 S 5 D 200 G/S 5 D 250 G S 5 D 310 Z 280 M8 M8 M10 M8 M6 M6 M10 M10 M10 25 20 45 25 10 10 90 30 60 Nm Nm Nm Nm Nm Nm Nm Nm Nm

AZD23-5.frb

20/10/97

23 - 5

Manual transmission

Type

Screw

Measure

Unit

23 11 Case and Covers

11AZ Plug in rear casing section All 240 260/280 12AZ 13AZ 14AZ 15AZ Sealing caps on rear case section Reversing bolt to reversing lever Clamping claws to rear case section Screws on detent plate 240/260/280 ZF S-5-16/S 5 D 310 Z ZF S-5-16/S 5 D 310 Z ZF S-5-16/S 5 D 310 Z M20 M16 M22 M6 60 40 60 10 43 33 9 Nm Nm Nm Nm Nm Nm Nm

AZD23-6.frb

20/10/97

23 - 6

Manual Transmission

Type

Screw

Dimensio n

Unit

23 11 Case and Cover

16AZ 17AZ Holder to transfer case Retaining plates for bearings on housing 265 Sport S 5 D 310 Z/S 5 D 200 G/250 G M6 M6 9 10 Nm (ft. lbs.) Nm (ft. lbs.)

AZD23-7.frb

20/10/97

23 - 7

Manual transmission

Type

Screw

Measure

Unit

23 21 Transmission Shafts

1AZ Output flange Collar nut installed with bolt cement initial torque loosen final torque 2AZ Gear wheel to layshaft 265 Sport M10 120 60 Nm Nm All

190

Nm

AZD23-8.frb

20/10/97

23 - 8

Manual transmission

Type

Screw

Measure

Unit

23 31 Interior Shift Components

1AZ Shift arms to transmission case S 5 D 310 Z 45 Nm

AZD23-9.frb

20/10/97

23 - 9

Manual transmission

Type

Screw

Measure

Unit

23 71 Transmission mounts

1AZ 2AZ Transmission mounts (rubber) to body Transmission cross member to body All All All 3AZ Mount bracket to transmission All M10 M10 M8 M8 42 42 21 21 Nm Nm Nm Nm

AZD24-1.frb

20/10/97

24 - 1

Automatic Transmission

Type

Screw

Dimensio n

Unit

24 00 Transmission in General

1AZ Transmission to engine Hex screws Hex screws Hex screws Torx bolts Torx bolts Torx bolts 2AZ Reinforcement plate to transmission All All All All All All All M8 M10 M12 M8 M10 M12 M8 24 45 82 21 42 72 23 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD24-2.frb

20/10/97

24 - 2

Automatic Transmission

Type

Screw

Measure

Unit

24 11 Transmission Case, Oil Sump

1AZ Transmission extension All A4S 270R/A4S 310R 2AZ 3AZ Guard Converter bell housing All All 4HP-22/4HP-24 A4S 270R/A4S 310R 4AZ Plug on transfer plate All 4HP-22/4HP-24 4HP-22/4HP-24 M8 5/16" M6 M8 M10 1/2" M10 M14 M20 25 32 9 25 46 42 16 40 50 Nm Nm Nm Nm Nm Nm Nm Nm Nm

AZD24-3.frb

20/10/97

24 - 3

Automatic Transmission

Type

Screw

Measure

Unit

24 11 Transmission Case, Oil Sump

5AZ Oil Pan 4HP-22/4HP-24/A5S 310Z A5S 300J A4S 270R/A4S 310R A5S 560Z/A5S 440Z 6AZ Oil drain plug All A4S 270R/A4S 310R A5S 300J A5S 560Z A5S 440Z 7AZ Oil filler plug A4S 270R/A4S 310R A5S 300J A5S 310Z/A5S 560Z A5S 440Z M18x1.5 M16x1.5 M6 M6 M10 M6 6 9 12 10 16 25 35 50 30 33 40 100 35 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm

AZD24-4.frb

20/10/97

24 - 4

Automatic Transmission

Type

Screw

Measure

Unit

24 11 Transmission Case, Oil Sump

8AZ Oil filler pipe 3HP-22 4HP-22/4HP-24/A5S 310Z 9AZ 10AZ Plug Oil bore plugs All A5S 300J A5S 310Z/A5S 560Z 11AZ 12AZ 13AZ Damper cover on transmission case Radial shaft seal on converter bell housing Intermediate plate on intermediate housing A5S 300J A4S 270R/A4S 310R A4S 270R/A4S 310R M6 M4 5/16" M18 105 98 43 8 15 10 3 25 Nm Nm Nm Nm Nm Nm Nm Nm

AZD24-5.frb

20/10/97

24 - 5

Automatic Transmission

Type

Screw

Measure

Unit

24 13 Transmission Extension, Bearings, Seals

1AZ Slotted nut/output flange A5S 310Z/A 5 S 440 Z/A5S 560Z 120 Nm

AZD24-6.frb

20/10/97

24 - 6

Automatic Transmission

Type

Screw

Measure

Unit

24 21 Input, Intermediate and Output Shafts

1AZ Output flange collar nut A5S 300J All others 225 100 Nm Nm

AZD24-7.frb

20/10/97

24 - 7

Automatic Transmission

Type

Screw

Measure

Unit

24 22 Planetary gear drive

1AZ Brake coupling D/G on gear box housing Insert all screws until contact is made with screw head in each case center bolt both outer screws center bolt both outer screws both outer screws 30 15 63 30 63 Nm Nm Nm Nm Nm A5S 310Z/A5S 560Z M10

AZD24-8.frb

20/10/97

24 - 8

Automatic Transmission

Type

Screw

Measure

Unit

24 23 Shift Clutches

1AZ Torx screws for F clutch on transmission case 4HP-22/4HP-24 A5S 560Z 2AZ 3AZ Brake band adjusting screw Lock nut of brake band adjusting screw A 4 S 270 R/A 4 S 310 R A 4 S 270 R/A 4 S 310 R M6 M8 5/16" 5/16" 10 23 5 21 Nm Nm Nm Nm

AZD24-9.frb

20/10/97

24 - 9

Automatic Transmission

Type

Screw

Measure

Unit

24 30 Hydr./elec.control elements

1AZ Valve body to transmission 3HP-22 4HP-22/4HP-24/A5S 310Z/ A5S 440Z/A5S 300J A4S 270R/A4S 310R A5S 560Z A5S 560Z 2AZ 3AZ Valve housing to valve body Adapter plate on shift unit All A4S 270R/A4S 310R M6 M6 11 8 Nm Nm

5/16" M6 x 12 M6x55 M6

20 6 8 5 13

Nm Nm Nm Nm Nm

AZD24-10.frb

20/10/97

24 - 10 Automatic Transmission

24 31 Primary Pump

1AZ Oil pump to case

Type

Screw

Measure

Unit

A4S 270R/A4S 310R 1st pass 2nd pass A5S 560Z A5S 560Z All others 2AZ Oil strainer A5S 440Z/A5S 560Z A5S 310Z A4S 270R/A4S 310R All others 3AZ Oil pump body A4S 270R/A4S 310R A5S 310Z/A5S 560Z 4AZ Oil cooler pipe adapter to transmission Hollow bolt Cap screw A5S 300J/A4S 270R/A 4 S 310 R A5S 440Z A5S 440Z

5/16" 10 20 M6 M5 M6 10 5 11 5 6 5/16" 20 8 5/16" M6 20 10 28 M18x1.5 M18x1.5 25 20 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm

AZD24-11.frb

20/10/97

24 - 11 Automatic Transmission

24 32 Governor

1AZ 2AZ 3AZ 4AZ 5AZ Governor flange to transmission Stud in centrifugal governor Hexagon nut on stud Hexagon head screw on centrifugal governor Governor housing to hub All All All All 4 HP-22 H

Type

Screw

Measure

Unit

M8 M6

16 3 10

Nm Nm Nm Nm Nm

M6 M6

11 11

AZD24-12.frb

20/10/97

24 - 12 Automatic Transmission

24 34 Shift Valves, Parking Lock

1AZ Pressure regulator to valve housing

Type

Screw

Measure

Unit

4HP-22 EH/4 HP-24EH/ A5S 310Z A4S 270R/A4S 310R

M6

5

Nm

10 M6 5 10 6 M5 M6 3 8 10 23 M5 M5 M5 M8 5 6 6 23 25 5

Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm

2AZ

Solenoid valve to valve housing

4HP-22 EH/4HP-24EH/A5S 310Z A4S 270R/A4S 310R A5S 560Z A5S 300J A5S 300J

3AZ

Guide plate/parking lock mechanism

A5S 310Z A5S 560Z

4AZ

Pulse sender

A5S 310Z/A5S 440Z A5S 300J A5S 560Z

5AZ 6AZ

Cover for servo piston on shift unit Retaining plate for solenoid valves and pressure regulator on shift unit

A4S 270R/A4S 310R A5S 440Z

5/16" M5

AZD24-13.frb

20/10/97

24 - 13 Automatic Transmission

24 35 Wire Harness, Shift Elements and Sensor

1AZ Transmission socket to case

Type

Screw

Measure

Unit

4HP-22 EH/4HP-24EH/A5S 310Z A4S 270R/A4S 310R

M26 M26

12 14

Nm Nm

AZD24-14.frb

20/10/97

24 - 14 Automatic Transmission

24 40 Torque converter

1AZ Torque converter to flywheel All

Type

Screw

Measure

Unit

M8 M10

26 45

Nm Nm

A4S 270R/A4S 310R/A5S 310Z/ A5S 300J/A5S 440Z/A5S 560Z All others

M10

49

Nm

AZD24-15.frb

20/10/97

24 - 15 Automatic Transmission

24 51 External shift linkage

1AZ Selector lever on transmission All A5S 300J

Type

Screw

Measure

Unit

M8x1 M8

10 15

Nm Nm

AZD24-16.frb

20/10/97

24 - 16 Automatic Transmission

24 52 Interior Shift Elements

1AZ Shift segment to shaft

Type

Screw

Measure

Unit

A4S 310R/A4S 310R A5S 300J M14x1.5 5/16"

22 35 25

Nm Nm Nm

2AZ

Detent spring on shift unit

A4S 270R/A4S 310R

AZD24-17.frb

20/10/97

24 - 17 Automatic Transmission

24 71 Transmission mounts

1AZ 2AZ 3AZ 4AZ 5AZ Cross member to body Rubber mounts to cross member or transmission Support tube to engine subframe Rubber mounts to carrier pipe Carrier plate All All E36 E36 E36

Type

Screw

Measure

Unit

21 21 42 21 21

Nm Nm Nm Nm Nm

AZD25-1.frb

20/10/97

25 - 1

Shift Mechanism

Type

Screw

Measure

Unit

25 11 Shift Console - Manual Transmission

1AZ 2AZ 3AZ 4AZ 5AZ 6AZ Front console to shift console Shift console to transmission Rear shift console to body Aluminum shift arm console to transmission Aluminum shift arm to console Shift arm console to body All with sheet metal console All with sheet metal console All E30 M3 E30 M3 All except E31 E31 7AZ Adjustable shift rod (clamp) E31 25 23 11 21.5 11 21 9 23 Nm Nm Nm Nm Nm Nm Nm Nm

AZD25-2.frb

20/10/97

25 - 2

Shift Mechanism

Type

Screw

Measure

Unit

25 16 Shift Console - Automatic Transmission

1AZ 2AZ 3AZ 4AZ 5AZ Bowden cable on shift tower/transmission Clamping screw on shift lever Shift console to tunnel Switch to shift console Interlock cable on shift tower All All All All All 15 10 7 4.5 7 Nm Nm Nm Nm Nm

AZD26-1.frb

20/10/97

26 - 1

Propeller Shaft

Type

Screw

Measure

Unit

26 11 Propeller Shaft Complete

1AZ Universal joint to propeller shaft and transmission All All E31/E38/E39 E32/E34/E36/E39 E32/E34/E36/E38/E39 M3/M5 Aluminum propeller shaft: flexible disk on propeller shaft Aluminum propeller shaft: flexible disk on transmission 2AZ Coupling propeller shaft to transmission E39 E39 All E32/E31 3AZ Clamping ring for slide after installation in car All E30 Four Wheel Drive M10 8.8 M10 10.9 M14 M12 8.8 M12 10.9 M12 10.9 M12 10.9 M12 10.9 M10 M12 48 60 140 81 100 115 100 90 60 95 10 22 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm

AZD26-2.frb

20/10/97

26 - 2

Propeller Shaft

Type

Screw

Measure

Unit

26 11 Propeller Shaft Complete

4AZ Driveshaft to drive flange (rear axle) Version, universal joint: Compression nut After loosening connection only use ribbed nuts with higher tightening torque Finned nut Version, constant velocity joint: Compression nut Compression nut Finned nut Finned nut 5AZ Pivot to center propeller shaft journal with Loctite (Version without slide) Center mount to body All M10 64 Nm

All All

M10 M8

80 32

Nm Nm

All All All All

M10 M8 M10

64 43 70 97

Nm Nm Nm Nm

6AZ

All

21

Nm

AZD27-1.frb

20/10/97

27 - 1

Transfer Box - Four Wheel Drive -

Type

Screw

Measure

Unit

27 00 Transfer Box in General

1AZ 2AZ 3AZ 4AZ 5AZ 6AZ Transfer box to manual transmission Transfer box on automatic transmission Coupling to manual transmission and transfer box Case bolts Electromagnetic clutch to case Output flange Collar nut installed with Loctite 270 or Hylogrip bolt cement All All All All All All M10 M8 M12 M8 M8 42 23 90 25 25 110 Nm Nm Nm Nm Nm Nm

AZD27-2.frb

20/10/97

27 - 2

Transfer Box - Four Wheel Drive -

Type

Screw

Measure

Unit

27 00 Transfer Box in General

7AZ Plug All All All 8AZ Transmission cross member to rubber mounts Transmission cross member to body All All M24x1.5 M14 x 1.5 M18x1.5 M12 M8 33 33 23 80 24 Nm Nm Nm Nm Nm

AZD61-1.frb

20/10/97

61 - 1

General Electrical system

Type

Screw

Dimensio n

Unit

61 13 Plug Connections

1AZ 2AZ Door plug connection to body Fuse box Screws for safety fuse Ground or positive connections All All M6 5 5 Nm Nm

3AZ

All

5

Nm

AZD61-2.frb

20/10/97

61 - 2

General Electrical system

Type

Screw

Dimensio n

Unit

61 31 Switch

1AZ Temperature switch 91°C 99°C 2AZ Oil pressure switch Note: oil and screw in M10/M40/M42/M21/M51/M20/ M30/M50/M60/1/M60/2/M70/S70 S14/S50/S38/M43 3AZ 4AZ 5AZ Reversing light switch Light switch on instrument panel Transmission switch on shift block All E36/E38 All 40 Nm All All 14 14 Nm Nm

20 20 2 4.5

Nm Nm Nm Nm

AZD61-3.frb

20/10/97

61 - 3

General Electrical system

Type

Screw

Measure

Unit

61 35 Control Units, Modules

1AZ 2AZ Power window module to drive Screws on E-box E36 E38 1 + 0.5 4 Nm Nm

AZD61-4.frb

20/10/97

61 - 4

General Electrical system

Type

Screw

Dimensio n

Unit

61 61 Windshield Wipers

1AZ Wiper motor secured to wiper bracket E31LL/E38 E36/E31RL 2AZ 3AZ 4AZ Parked position stop to wiper console Wiper contact pressure motor to wiper console Motor crank to wiper motor SWF Bosch, Magnet Marelli 5AZ 6AZ Wiper shaft nut to body Holder to firewall screws in firewall E31/E36/E32/E34 E31 E38/E39/E36 Coupé M6 M8 M8 12 10 10 27 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) E31 E31/E32/E34/E38 M6 7.5 10 15 6.5 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD61-5.frb

20/10/97

61 - 5

General Electrical system

Type

Screw

Dimensio n

Unit

61 61 Windshield Wipers

7AZ 8AZ 9AZ 10AZ Upper cowl panel support Wiper support bracket to firewall Wiper support bracket to wiper console Wiper arms * after waiting for 15 minutes, retighten to torque E36 driver's side passenger's side driver's side with WCPC E31 E31/E32/E34/E38/E39 E32/E34 E38/E39 driver's side without WCPC E32/E34 E38 25* 40* 25* 21* 40 25* 25* Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.) E31 E36 E36 M4 5 10 10 Nm (ft. lbs.) Nm (ft. lbs.) Nm (ft. lbs.)

AZD61-6.frb

20/10/97

61 - 6

General Electrical system

Type

Screw

Dimensio n

Unit

61 62 Tailgate Window Wiper

1AZ 2AZ Wiper shaft to tailgate window Wiper console to tailgate (rubber mount) E34 touring E34 touring E36 comp/touring 3AZ 4AZ 5AZ Wiper motor to console Motor crank to wiper motor Wiper arm to wiper shaft E34 touring E34 touring E34/E36 Touring / E36 comp, touring E34 touring M6 5 5 10 13 13 13 Nm Nm Nm Nm Nm Nm

6AZ

Spray nozzle to tailgate

10

Nm

AZD61-7.frb

20/10/97

61 - 7

General Electrical system

Type

Screw

Measure

Unit

61 67 Headlight Cleaners

1AZ 2AZ Telescope to bracket Bracket to body E36 E36 3 15 Nm Nm

AZD62-1.frb

20/10/97

62 - 1

Instruments

Type

Screw

Measure

Unit

62 16 Car Electrical System Senders

1AZ Screws for speedometer sender All 6,6 ... 8,4 Nm

AZD71-1.frb

20/10/97

71 - 1

Equipment and Accessories for Engine and Chassis

Type

Screw

Measure

Unit

71 60 Trailer Hitch

1AZ Hitch to body: Tighten according to following sequence: 1. Hitch bolts 2. Axial strut bolts 3. Reinforcement bracket collar nut E36 M10 8.8 42 Nm

M10 10.9 2AZ Slotted nut for take-up pipe to hitch (use Loctite No. 638) E32 M40

59 220

Nm Nm

AZD72-1.frb

20/10/97

72 - 1

Equipment and Accessories for Engine and Chassis

Type

Screw

Measure

Unit

72 11 Seat belts

1AZ Safety belt on body, except for B-pillar Safety belt on B-pillar Safety belt on seat, on touring also on rear seat backrest 2AZ 3AZ Screws for seatbelt height adjustment on body Seat belt to seat Install bolt with bolt cement Seat belt to backrest Headrest to backrest Safety belt with belt height adjustment Tension relief between roller blind mount and backrest lock mount All All All All E31 48 31 48 24 47 Nm Nm Nm Nm Nm

4AZ 5AZ 6AZ 7AZ

E31 E31 All E39/2

24 24 31 24

Nm Nm Nm Nm

AZD72-2.frb

20/10/97

72 - 2

Equipment and Accessories for Engine and Chassis

Type

Screw

Measure

Unit

72 12 Airbag generator

1AZ 2AZ 3AZ 4AZ 5AZ Airbag module on doors Gas generator of ITS head airbag on body Bracket of ITS head airbag on body ITS head airbag on body Additional steel bracket for ITS head airbag on body E36, E38, E39 E38 E38 E38 E38 L7 Self-tapping M5 threaded bolt self-tapping screw 11 4 2.5 11 3 Nm Nm Nm Nm Nm

Information

136 pages

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