12 41 020 Removing and installing/replacing starter motor (M54 4WD xi)

WARNING: This page does not describe the selected car, but rather 15 other vehicles, including the 2005 BMW 325xi, 2005 BMW 325i, 2005 BMW 325Ci, 2004 BMW 325xi, and 2004 BMW 325i. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools Required:

00 2 030
24 5 301
24 5 305

Follow instructions for disconnecting and connecting battery, refer to 12 00... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Disconnect and cover battery negative terminal.

release screws (1) and remove cover (2).

Fig 1: Releasing Screws (1) And Removing Cover (2)

G00403222

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: To release the starter motor bolt connection on the transmission, it is necessary to lower the transmission by approx. 5 cm.

Lowering the transmission is described in the section "Removing and installing transmission".

To lower transmission:

Remove intake hood.
Remove underbody protection.
Remove exhaust system.
Remove heat shield.
Remove shift lever and cable.
Detach propeller shaft from transmission and tie back to one side.
Remove front propeller shaft.
Support transmission with special tool 00 2 030/24 5 301/24 5 305.
Remove cross-member.

If fitted:

Remove vacuum reservoir for exhaust flap.

unclip fuel line (1) from holders (2).

Fig 2: Uncliping Fuel Line (1) From Holders (2)

G00403223

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: For a better overview, this work step is shown on an engine that has been removed.

unlock plug (1) of crankshaft pulse generator and disconnect.

Fig 3: Unlocking Plug (1) Of Crankshaft Pulse Generator And Disconnecting

G00403224

Courtesy of BMW OF NORTH AMERICA, INC.

release nut (1) and disconnect battery positive leads from starter motor.

Fig 4: Releasing Nut (1) And Disconnecting Battery Positive Leads From Starter Motor

G00403225

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Tightening torque: 45 N.m.

Release nuts (1).

Installation:

Tightening torque: 45 N.m.

remove lines (2) from starter motor.

Fig 5: Remove Lines (2) From Starter Motor

G00403226

Courtesy of BMW OF NORTH AMERICA, INC.

release both starter motor mounting bolts (1) on transmission.

Fig 6: Releasing Both Starter Motor Mounting Bolts (1) On Transmission

G00403227

Courtesy of BMW OF NORTH AMERICA, INC.

Release starter mounting bolts from transmission output end with a long extension and a universal joint.

Installation:

Tightening torque: 45 N.m.

withdraw starter motor (1) from transmission flange and remove towards bottom.

Fig 7: Withdrawing Starter Motor (1) From Transmission Flange And Removing Towards Bottom

G00403228

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

check starter motor pinion and ring gear for damage.

Fig 8: Checking Starter Motor Pinion And Ring Gear For Damage

G00403229

Courtesy of BMW OF NORTH AMERICA, INC.