Alpina B5, B6 User Manual
Burkard Bovensiepen GmbH+Co. KG
Alpenstraße 35-37,D-86807 Buchloe
Repair Instructions
BMW ALPINA B5 / B6
Repair Instructions
BMW ALPINA B5
BMW ALPINA B6
Dwg.-No. Page 1 of 20
88 03 357
Prepared by Date
Customer service 04.10.2005
Updated as of:
04.02.2008
Expert automotive knowledge is required.
These Repair Instructions are based on the BMW 545i/550i/650i TIS Repair Instructions.
If Nm torque settings are not shown, please see the BMW 545i/550i/650i
TIS Repair Instructions.
Burkard Bovensiepen GmbH+Co. KG
Alpenstraße 35-37,D-86807 Buchloe
Repair Instructions
BMW ALPINA B5 / B6
Dwg.-No. Page 2 of 20
88 03 357
Prepared by Date
Customer service 04.10.2005
Updated as of:
04.02.2008
OVERVIEW / TABLE of CONTENTS:
Page
Installing, removing and replacing the radial compressor 3
Checking the radial compressor’s clutch for wear / replacement 6
Installing, removing and replacing the radiator cooling package 9
Disassembly and assembly of the radiator cooling package 12
Disassembly and assembly of the catalytic converters 16
Disassembly and assembly of the DSC Hydro Unit 17
Disassembly and assembly of the automatic transmission 18
Renewing rear diff. oil 19
Exchange of spark plugs 20
Burkard Bovensiepen GmbH+Co. KG
Alpenstraße 35-37,D-86807 Buchloe
Repair Instructions
BMW ALPINA B5 / B6
Installing, removing and replacing the radial
compressor
WARNING!
Danger of burns! Perform the following job on the
vehicle only once it has completely cooled down.
ATTENTION!
The intercooler’s hoses could fail if not installed when
dry and free of any grease or oils. Please ensure a
grease-free and dry installation.
Dwg.-No. Page 3 of 20
88 03 357
Prepared by Date
Customer service 04.10.2005
Updated as of:
04.02.2008
2
1
Remove engine cover
(1), back out bolt (2) and loosen
clamps (3). Remove air intake tract and intercooler
3
Back out bolts (4) and remove belt cover.
hose.
ATTENTION! Bolts (4) have to be replaced by the
4
delivered ones ALPINA 11 65 701 and screwed in with
Loctite.
Unplug electrical connectors leading to the boost
1
pressure regulator (3) and the crankcase ventilator (1)
and open the cable ties (2).
3
ATTENTION! Don´t turn ignition on while the power
pressure regulator (3) is disconnected!
2
ATTENTION! During assembly: ensure the correct
mounting of the rubber seal within the black air intake
tract!
1
Press the belt tensioner (1) back to its stops using
ALPINA special tool 74 00 643 or 60 Torx Socket:
and remove the drive belt.
Burkard Bovensiepen GmbH+Co. KG
Alpenstraße 35-37,D-86807 Buchloe
Repair Instructions
BMW ALPINA B5 / B6
Dwg.-No. Page 4 of 20
88 03 357
Prepared by Date
Customer service 04.10.2005
Updated as of:
04.02.2008
Unscrew the radial compressor’s mounting bolts (2)
and remove the radial compressor.
1
2
Dismount pulley wheel.
Dismount tube (1) and screw it to the new radial
compressor.
Torque the screws to 8,8Nm.
ATTENTION: use new O-ring.
Pay careful attention that the positioning dowels (3) are
3
properly fitted, that the oil passages are clean.
Ensure that you don´t damage the oil passages while
remounting the radial compressor.
When exchanging the compressor, take over distance
spacer (1), tube (2) and a new O-ring into the
new radial compressor.
Tightening torque of tube screws: 8,8 Nm.
1
Dismount power pressure regulator.
2
Burkard Bovensiepen GmbH+Co. KG
Alpenstraße 35-37,D-86807 Buchloe
Repair Instructions
BMW ALPINA B5 / B6
Install spacer (1). Rotate the spacer such that the
1
holes in the spacer line up with the bore holes in
the clutch housing.
Check pulley disc for cracks and replace if
necessary.
Install the pulley disc.
Hand-tighten the bolts in a cross-wise pattern.
Check the belt housing to ensure it is running true
on centre.
ATTENTION! Tighten screws with torque wrench
after mounting the compressor´s belt (see below).
Dwg.-No. Page 5 of 20
88 03 357
Prepared by Date
Customer service 04.10.2005
Updated as of:
04.02.2008
Install the boost pressure regulator (2) and pay
attention to the correct position of the gasket.
Torque screws to 8,8 Nm.
2
Install radial compressor.
ATTENTION:
Mount the radial compressor straight on the
bracket, ensure the correct mounting of the belt
cover brackets and pay attention to the correct
lenght of the screws: 8x30 font; 8x35 rear
(mounting bolt torque: 21 Nm.)
Carefully push back the belt tightener to its stop,
mount the compressor belt and check that it is
properly seated.
Torque the belt housing screws cross-wise to
9 Nm.
Start the engine and check the belt drive.
ATTENTION: danger of injury from moving
parts.
Complete assembly.
ATTENTION:
the testdrive!
Erase the fault memory before
Burkard Bovensiepen GmbH+Co. KG
Alpenstraße 35-37,D-86807 Buchloe
Repair Instructions
BMW ALPINA B5 / B6
Checking the radial compressor’s clutch for wear /
replacement
Remove radial compressor (see ALPINA repair
instructions)
ATTENTION! Ensure that the oil passages stay
clean and that you don´t damage the oil
passages of the radial compressor.
Unscrew the bolts from the radial compressor’s
pulley disc and remove the pulley disc as shown
in picture (1).
Dwg.-No. Page 6 of 20
88 03 357
Prepared by Date
Customer service 04.10.2005
Updated as of:
04.02.2008
.
Remove spacer (1).
Pull the centrifugal clutch’s (1) weights and friction
pads out of the clutch housing using two needle
nose pliers.
Loading...