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Burkard Bovensiepen GmbH+Co. KG |
Dwg.-No. |
Page 1 of 20 |
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Alpenstraße 35-37,D-86807 Buchloe |
88 03 357 |
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Repair Instructions |
Prepared by |
Date |
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Customer service |
04.10.2005 |
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BMW ALPINA B5 / B6 |
Updated as of: |
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04.02.2008 |
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Repair Instructions
BMW ALPINA B5
BMW ALPINA B6
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.
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Burkard Bovensiepen GmbH+Co. KG |
Dwg.-No. |
Page 2 of 20 |
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Alpenstraße 35-37,D-86807 Buchloe |
88 03 357 |
|
|
Repair Instructions |
Prepared by |
Date |
|
Customer service |
04.10.2005 |
|
|
BMW ALPINA B5 / B6 |
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 |
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Burkard Bovensiepen GmbH+Co. KG |
Dwg.-No. |
Page 3 of 20 |
|
Alpenstraße 35-37,D-86807 Buchloe |
88 03 357 |
|
|
Repair Instructions |
Prepared by |
Date |
|
Customer service |
04.10.2005 |
|
|
BMW ALPINA B5 / B6 |
Updated as of: |
|
|
|
04.02.2008 |
|
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.
2
1
3
4
1
3
2
1
Remove engine cover (1), back out bolt (2) and loosen clamps (3). Remove air intake tract and intercooler hose. Back out bolts (4) and remove belt cover. ATTENTION! Bolts (4) have to be replaced by the delivered ones ALPINA 11 65 701 and screwed in with Loctite.
Unplug electrical connectors leading to the boost pressure regulator (3) and the crankcase ventilator (1) and open the cable ties (2).
ATTENTION! Don´t turn ignition on while the power pressure regulator (3) is disconnected!
ATTENTION! During assembly: ensure the correct mounting of the rubber seal within the black air intake tract!
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.
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Burkard Bovensiepen GmbH+Co. KG |
Dwg.-No. |
Page 4 of 20 |
|
Alpenstraße 35-37,D-86807 Buchloe |
88 03 357 |
|
|
Repair Instructions |
Prepared by |
Date |
|
Customer service |
04.10.2005 |
|
|
BMW ALPINA B5 / B6 |
Updated as of: |
|
|
|
04.02.2008 |
|
Unscrew the radial compressor’s mounting bolts (2) and remove the radial compressor.
1 |
2 |
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3
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 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
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Burkard Bovensiepen GmbH+Co. KG |
Dwg.-No. |
Page 5 of 20 |
|
Alpenstraße 35-37,D-86807 Buchloe |
88 03 357 |
|
|
Repair Instructions |
Prepared by |
Date |
|
Customer service |
04.10.2005 |
|
|
BMW ALPINA B5 / B6 |
Updated as of: |
|
|
|
04.02.2008 |
|
Install spacer (1). Rotate the spacer such that the holes in the spacer line up with the bore holes in
1the 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).
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Install the boost pressure regulator (2) and pay |
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attention to the correct position of the gasket. |
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Torque screws to 8,8 Nm. |
2 |
Install radial compressor. |
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ATTENTION: |
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Mount the radial compressor straight on the |
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bracket, ensure the correct mounting of the belt |
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cover brackets and pay attention to the correct |
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lenght of the screws: 8x30 font; 8x35 rear |
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(mounting bolt torque: 21 Nm.) |
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Carefully push back the belt tightener to its stop, |
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mount the compressor belt and check that it is |
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properly seated. |
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Torque the belt housing screws cross-wise to |
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9 Nm. |
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Start the engine and check the belt drive. |
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ATTENTION: danger of injury from moving |
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parts. |
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Complete assembly. |
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ATTENTION: Erase the fault memory before |
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the testdrive! |
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Burkard Bovensiepen GmbH+Co. KG |
Dwg.-No. |
Page 6 of 20 |
|
Alpenstraße 35-37,D-86807 Buchloe |
88 03 357 |
|
|
Repair Instructions |
Prepared by |
Date |
|
Customer service |
04.10.2005 |
|
|
BMW ALPINA B5 / B6 |
Updated as of: |
|
|
|
04.02.2008 |
|
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).
Remove spacer (1).
Pull the centrifugal clutch’s (1) weights and friction pads out of the clutch housing using two needle nose pliers.
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