Alpina D10 User Manual
Burkard Bovensiepen GmbH+Co.
Alpenstraße 35-37,D-86807 Buchloe
Service Manual
Dwg.-Nr. Page 1 of 25
88 03 175
Prepared by Date
Engineering 20 July 2000
BMW/ALPINA D10 BITURBO
Service Manual
BMW / ALPINA D10 Biturbo
The servicing covered herein should be undertaken by qualified mechanics only.
This manual has been based on the service manual for the BMW 530d.
All torque specifications are listed in the service manual for the BMW 530d.
Burkard Bovensiepen GmbH+Co.
Alpenstraße 35-37,D-86807 Buchloe
Service Manual
Dwg.-Nr. Page 2 of 25
88 03 175
Prepared by Date
Engineering 20 July 2000
BMW/ALPINA D10 BITURBO
Contents:
Page
11 61 Checking the swirl flaps for proper operation 3
11 62 Removing and reinstalling, sealing, or replacing the exhaust manifolds 4
11 65 Removing and reinstalling/replacing the exhaust-gas turbochargers 5
11 71 Removing and reinstalling/replacing the EGR-system 10
13 51 Removing and reinstalling/replacing the high-pressure fuel pump 14
13 53 Removing and reinstalling/replacing the fuel distributor 19
18 00 Removing and reinstalling/replacing the exhaust system as a unit 22
18 31 Removing and reinstalling/replacing the precatalyst 24
Burkard Bovensiepen GmbH+Co.
Alpenstraße 35-37,D-86807 Buchloe
Service Manual
Dwg.-Nr. Page 3 of 25
88 03 175
Prepared by Date
Engineering 20 July 2000
BMW/ALPINA D10 BITURBO
11 61 Checking the swirl flaps for proper operation
The swirl flaps are actuated by the linkage (1)
whenever the vehicle’s engine is started, shut off, or
reaches approximately 2.200 rpm.
1
Burkard Bovensiepen GmbH+Co.
Alpenstraße 35-37,D-86807 Buchloe
Service Manual
BMW/ALPINA D10 BITURBO
11 62 Removing and reinstalling, sealing, or replacing
the exhaust manifolds
Warning!
Burn hazards!
Do not attempt any of the following servicing operations
until the vehicle’s engine has cooled down.
Caution!
Installing charge-air hoses that are not perfectly dry and
free of grease can cause a failure of the charge-air
system.
Make certain that the charge-air hoses are perfectly dry
and free of grease before reinstalling them.
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Refer to p. 5 of this manual for instructions on removing
and reinstalling the exhaust-gas turbochargers.
Remove the nuts (1) holding the exhaust manifolds in
place and remove both exhaust manifolds.
1
Reinstalling the exhaust manifolds:
- Use all new gaskets and seals.
- Coat the threads on the manifold studs with a thin
layer of copper paste (CRC), which is available from
1
BMW’s parts department.
- Replace the nuts (1) with new nuts.
- Torque the nuts down, working from the centers of the
exhaust manifolds toward their outer ends.
Burkard Bovensiepen GmbH+Co.
Alpenstraße 35-37,D-86807 Buchloe
Service Manual
BMW/ALPINA D10 BITURBO
11 65 Removing and reinstalling / replacing the exhaust-
gas turbochargers
Warning!
Burn hazards!
Do not attempt any of the following servicing operations
until the vehicle’s engine has cooled down.
Caution!
Installing charge-air hoses that are not perfectly dry and
free of grease can cause a failure of the charge-air
system.
Make certain that the charge-air hoses are perfectly dry
and free of grease before reinstalling them.
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Refer to p. 24 of this manual for instructions on
removing and reinstalling the precatalysts.
Drain approximately 3 liters of motor oil from the
crankcase.
Remove the fan cowl.
Refer to Dwg. No. 17 11 031 for instructions on
removing and reinstalling the fan cowl.
Remove the screws (1) holding the silencer shroud (2)
in place and slide the silencer shroud forward.
Lift off the silencer shroud.
Burkard Bovensiepen GmbH+Co.
Alpenstraße 35-37,D-86807 Buchloe
Service Manual
BMW/ALPINA D10 BITURBO
Release the clips (1) and withdraw the air duct, as
shown by the arrow.
Release the clamping bail (2).
Remove the cover (3) from the microfilter housing.
Open the clamp (4).
Rotate the microfilter housing in the direction of the
arrow and withdraw it upward.
Remove the intake duct assembly (1).
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1
Remove the cap (1).
Remove the screws (2) holding the air-filter cover (3) in
place.
Lift off the air-filter cover (3).
Remove the airduct mounting bolts (1).
1
Burkard Bovensiepen GmbH+Co.
Alpenstraße 35-37,D-86807 Buchloe
Service Manual
Dwg.-Nr. Page 7 of 25
88 03 175
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Engineering 20 July 2000
BMW/ALPINA D10 BITURBO
Loosen the clamps (1) on the molded hoses.
Remove the crankcase-ventilation hose (2).
Remove the distributor on the air-intake duct complete
1
3
2
with the intake duct for Turbocharger 1 by pulling it
forward.
Remove the intake duct (3) for Turbocharger 2.
Remove the clamp (1).
Remove the fittings fastening the EGR-lines to the rear
exhaust manifold and the nuts on the flange (2).
Remove the rear EGR-line.
Remove the fitting fastening the EGR-line to the front
exhaust manifold.
1
2
Vehicles equipped with manual transmissions only:
1
Remove the bolt and nut (1) holding the fitting in place.
Loosen the clamp (2) and remove the front EGR-line.
2
Vehicles equipped with automatic transmissions
only:
Loosen the clamp (1) and remove the front EGR-line.
1
Burkard Bovensiepen GmbH+Co.
Alpenstraße 35-37,D-86807 Buchloe
Service Manual
BMW/ALPINA D10 BITURBO
Unscrew the hollow bolt (1).
Remove the oil lines (2).
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2
Note:
Seal the fittings for the oil lines and the openings in the
1
crankcase housing using suitable caps or plugs.
Note on reinstallation:
New seals are to be used when reinstalling
components.
Loosen the clamp (1) on the hose (2) on the front
1
2
turbocharger’s exit port and remove the hose (2).
1 4
Loosen the clamp (1) on the oil-return hose and remove
the oil-return hose.
Unscrew the oil-return tube (2) on the turbocharger.
Loosen the clamp (3) on the hose (4) on the rear
turbocharger’s exit port and remove the hose (4).
3
2
Remove the tube on the intercooler intake port and
move it aside.
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