Engine - Repair (s54) — BMW M3 E46 (1999-2006)

00 00 250 BMW Engine Oil Service Incl. Supplementary Service (S54)

Note. Work step 00 00 250 comprises the engine oil and supplementary services.

Only the engine oil service will be described in these repair instructions.

For the supplementary service work steps, refer to the vehicle-specific inspection sheet.

Engine Oil Service

Note. When the main flow oil-filter cover is released, the oil flows from the oil-filter housing back into the sump.

Unfasten oil filter cover.

Installation

Scheme 2

Scheme 2: 00 00 250 BMW Engine Oil Service Incl. Supplementary Service (S54)

Tightening torque, refer to 11 42 2AZ in «ENGINE - TIGHTENING TORQUES»(ref-201358) .

Installation

Scheme 3

Replace sealing ring in oil-filter cover and sealing ring on bolt.

Replace oil filter element (1).

Scheme 4

Drain or draw off engine oil. If engine oil is drained

E46 Only

Lever out cover (1) on side with a screwdriver.

Scheme 5

Open oil drain plug and drain off engine oil.

Installation

Scheme 6

Replace sealing ring.
Tightening torque, refer to 11 13 1AZ in «ENGINE - TIGHTENING TORQUES»(ref-201358) .

Complete vehicle and set in horizontal position. Top up engine oil.

Start engine and run at idle until oil indicator lamp goes out. Switch off engine, wait approx. 5 minutes and then check engine oil level.

Top up engine oil if necessary.

Supplementary Service

Refer to vehicle-specific inspection sheet.

11 00 039 Checking Compression Of All Cylinders (S54)

Note. For Special Tool identification, see SPECIAL TOOLS - M3 .

Special Tools Required

11 0 224
11 0 235

Read out fault memory of DME control unit.
Check stored faults.
Rectify faults.
Clear fault memory.

Disconnect fuel pump relay or fuel pump fuse. Start engine and allow remaining fuel to escape. This prevents fuel from being injected, the catalytic converter from being damaged and the test result from being distorted during the compression pressure check.

CAUTION

High tension - danger!

Disconnect all supply leads from ignition coils (interrupt power supply to ignition coils).

Remove lower microfilter section (E46 only).
Remove ignition coil cover.
Remove ignition coils. See «12 13 511 REPLACING IGNITION COIL (S54)»(/bmw/m3/e46-1999-2006/remont/gauges-instrument-panels/#engine-electrical-system-repair__12-13-511-replacing-ignition-coil)
Remove all spark plugs. See «12 12 011 REPLACING ALL SPARK PLUGS (S54)»(/bmw/m3/e46-1999-2006/remont/gauges-instrument-panels/#engine-electrical-system-repair__12-12-011-replacing-all-spark)

Note. Check that sealing ring is in perfect condition on special tool 11 0 235.

Screw special tool 11 0 235 by hand into spark plug thread and connect special tool 11 0 224.

Depress accelerator and actuate starter until compression stops rising.

Compression pressure, refer to ENGINE - TECHNICAL DATA .

Scheme 7

Now clear the fault memory.

11 00 045 Checking Absolute Compression Of All Cylinders

With BMW Diagnosis Information System (DIS).

Scheme 8

Scheme 8: 11 00 045 Checking Absolute Compression Of All Cylinders

Connect DIS tester.
BMW measuring technology.
Preset measurements.
Absolute compression. The further procedure is described in: Help. Help on preset measurements. Adaptation of "Absolute compression".
Clear fault memory.

11 00 050 Removing and installing engine (S54)

Special Tools Required

11 0 000
51 2 160

Instructions for disconnecting and connecting battery. Refer to «12 00... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY»(/bmw/m3/e46-1999-2006/remont/gauges-instrument-panels/#engine-electrical-system-repair__12-00-instructions-for-disconnecting) .
Disconnect negative battery lead.

Move engine hood to assembly position

Note. The following work must be carried out with a second person assisting. Work instruction applies to left and right sides.

Gently raise retaining clip and simultaneously push upwards.

Scheme 9

Hold engine hood, unhook damper on hood.

Slide special tool 51 2 160 over damper.

Open engine hood completely and reconnect damper with special tool 51 2 160 to hood.

Scheme 10

Remove microfilter.

Open cable duct on lower section of microfilter housing (2) and feed out cable(s).

Release screws (1) and remove lower section of microfilter Housing (2)

Scheme 11

Remove engine vent (1).

Remove oil filler cap (2).

Remove engine cover.

Scheme 12

Remove engine splash guard.

Remove reinforcement plate.

CAUTION

The article 51 71 374 REMOVING AND INSTALLING / REPLACING REINFORCEMENT PLATE ON FRONT AXLE SUPPORT (M3) , contains important installation instructions.

Remove A/C compressor drive belt. Refer to 11 28 050 REPLACING A/C COMPRESSOR DRIVE BELT (S54) .

Remove A/C compressor from bearing block and tie back to one side.

Note. Lines remain connected.

Drain and dispose of coolant.

Note. The water drain plug is located on the exhaust side on cylinder 2 in the engine block.

Installation

Replacing sealing ring on water drain plug.
Tightening torque, (25 N.m.).

Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54) .

Remove throttles. Refer to 13 54 030 REMOVING AND INSTALLING/SEALING THROTTLE ASSEMBLY (S54) .

Pull lock and detach water hoses (1 and 2).

Installation

Scheme 13

Refer to «17 00... INSTRUCTIONS FOR WORKING ON COOLING SYSTEM.»(/bmw/m3/e46-1999-2006/remont/cooling-system-mechanical/#cooling-system-repair__17-00-instructions) .

Drain power steering supply tank, detach from left carrier bracket and tie to one side.

Note. Lines remain connected.

Remove fan clutch with fan impeller from water pump. Refer to 11 52 020 REMOVING AND INSTALLING/REPLACING FAN CLUTCH (S52 / S54 / M52 / M52TU / M54 / M56) .

Remove engine oil cooler.

Remove radiator. Refer to 17 11 000 REMOVING AND INSTALLING RADIATOR (S54) .

Remove alternator drive belt. Refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT (S54) .

Remove vane pump for power steering and tie back to one side.

Note. Lines remain connected.

Note. Wiring harness section for engine is disconnected from car and removed with engine.

Disconnect plug connections on DME control unit. Disconnect wiring harness section from car and lay to engine.

Note. When the engine is being lifted out, there is the danger that the belt pulley may be damaged.

Unfasten screws. Remove belt pulley

Scheme 14

Remove transmission. See REMOVAL & INSTALLATION - M3 (S6S 420G SMG)

Remove starter motor. See STARTER

Detach steering spindle from steering gear. Refer to POWER STEERING GEAR .

CAUTION

Only raise engine on locating lugs provided for this purpose.

Fit engine to special tool 11 0 000.

Scheme 15

Unfasten right ground wire.

Unscrew left and right engine mounts.

Carefully lift out engine.

11 12 000 Removing And Installing, Sealing Cylinder Head Cover (S54)

E46 Only

Remove microfilter

Scheme 16

Scheme 16: 11 12 000 Removing And Installing, Sealing Cylinder Head Cover (S54)

E46 Only

Open cable duct on lower section of microfilter housing and feed out cable(s).

Scheme 17

E46 Only

Release screws (1) and remove lower section of microfilter housing (2)

Scheme 18

E46 Only

Remove expansion rivets. Remove air duct (1).

Scheme 19

Remove hose (1) for engine vent.

Remove sealing cap (2).

Remove ignition coil cover.

Scheme 20

Disconnect plug connection (1) on sensor of exhaust camshaft.

Note. Illustration shows: US version.

Scheme 21

Installation

The cables of the oxygen sensors are clipped into mounts on the shield plate of the exhaust manifold.

CAUTION

Ensure cables are exactly routed.

CAUTION

It is very easy for the sealing ring between the cylinder head cover and the return line to drop into the engine.

Carefully release hollow screw (1) and remove sealing ring between cylinder head cover and return line.

Installation

Replace sealing rings.

Tightening torque 25 N.m.

Detach grounding strap (2) for ignition coils from cylinder head.

Scheme 22

Note. The plug housings of the oxygen sensors for cylinders 1 to 3 and 4 to 6 are different.

Unclip plug housing (1) from mounting.

Disconnect plug connections of oxygen sensors.

Feed oxygen sensor cables out of cable guide and lay to one side.

Remove ignition coils. Refer to 12 13 511 REPLACING IGNITION COIL (S54) .

Lay ignition coil and oxygen sensor cables to one side.

Scheme 23

Remove cylinder head cover (1)

Scheme 24

Installation

Scheme 25

Remove sealing debris from sealing faces of cylinder head and cylinder head cover.
Apply a sealing bead of Drei Bond 1209 on left and right sides at transition between cylinder head and VANOS adjustment unit.

Note. Illustration with engine removed.

Installation

Scheme 26

Apply a thin and even sealing bead of Drei Bond 1209 at transition to half-moon sections at rear of cylinder head.

Installation

Replace sealing rings (1).

Scheme 27

Note. The gasket of the cylinder head cover is secured with guide pins on the cylinder head and on the VANOS adjustment unit.

Installation

Replace gasket of cylinder head cover. Preassemble gasket of cylinder head cover on cylinder head.

CAUTION

The guide pins may buckle very slightly during installation. Make sure that guide pins are exactly fed into bore holes.

Scheme 28

Illustration with engine removed.

Installation

Scheme 29

Make sure gasket is correctly seated on rear and front ends of cylinder head.

CAUTION

Different rubber gaskets: Front low version.

Installation

Replace rubber gaskets.

Install all cap nuts and align cylinder head cover.

Fit all cap nuts without pretension. Tighten down cap nuts in diagonal sequence from inside to outside.

Scheme 30

11 12 100 Removing And Installing/Sealing Cylinder Head (S54)

Note. For Special Tool identification, see SPECIAL TOOLS - M3 .

Special Tools Required

11 4 400
12 1 120

Remove both exhaust manifolds. Refer to 11 62 140 REMOVING AND INSTALLING, SEALING/REPLACING BOTH EXHAUST MANIFOLDS (S54) .

Remove intake filter housing with air-mass flow sensor. Refer to 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING (S54) .

Remove cylinder head cover. Refer to 11 12 000 REMOVING AND INSTALLING, SEALING CYLINDER HEAD COVER (S54) .

Remove all spark plugs. See 12 12 011 REPLACING ALL SPARK PLUGS (S54)

Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54) .

Remove coolant drain plug in engine block. Drain and dispose of coolant.

Installation

Tightening torque, (25 N.m.).
Vent cooling system and check for leaks. Refer to «17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR LEAKS (S54)»(/bmw/m3/e46-1999-2006/remont/cooling-system-mechanical/#cooling-system-repair__17-00-039-venting-cooling-system) .

Removal

Removal of cylinder head is described separately from installation.

Remove camshafts. Refer to 11 31 019 REPLACING CAMSHAFTS (S54) .

CAUTION

It is very easy for the adjustment plates to fall down.

Raise rocker arm.

Note. Special tool 11 4 400 is magnetic.

Remove all adjustment plates with special tool 11 4 400 and set to one side in order.

Scheme 31

CAUTION

The connector strip may break if it is removed without special tool 12 1 120.

Unlock connector strip with special tool 12 1 120 in sequence 1 to 6.

Scheme 32

Press lock and detach hose from supplementary air line.

Scheme 33

Detach bracket for idle-speed control valve from return line and lay with hoses to one side.

Disconnect plug connection (1) to temperature sensor.

Scheme 34

Remove thermostat housing (1).

Installation

Replace sealing rings.

Remove belt pulley (2).

Remove pipe (3).

Scheme 35

Note. Illustration with engine removed.

Pull off vacuum hose (1).

Feed out upper cover section (2) towards top.

Detach wiring harness from retaining lug (3).

Pull connector strip (4) upwards.

Disconnect plug connection to camshaft sensor of inlet and exhaust camshafts.

Disconnect plug connection to throttle actuator.

Lay connector strip (4) to one side.

Scheme 36

Remove pull rod (1).

Unfasten screws.

Note. Do not remove pipe (2).

Scheme 37

Unlock water hose (1) and detach from return line.

Release upper screw of fuel feed line (2) from return line.

Scheme 38

Release lower screw of fuel feed line (2) from engine block.

Scheme 39

Detach retaining clip (1) of fuel feed line.

Note. Catch and dispose of escaping fuel.

Pull fuel feed line downwards.

Scheme 40

Note. The thrust bearing flange (1) and the cylinder head are machined as a single unit and must not be replaced individually.

Remove thrust bearing flange (1).

Scheme 41

Note. Sliding rail (1) is screwed to cylinder head.

Release screw (2).

Scheme 42

Release screws between cylinder head and timing case cover. Remove cable holder (1).

Scheme 43

Release cylinder head bolts from outside to inside in sequence 14 to 1.

Lift off cylinder head.

Scheme 44

Installation

Installation of cylinder head is described separately from removal.

Clean sealing faces of cylinder head and engine block; if necessary, remove traces of gasket with hardwood spatula. Make sure no gasket remnants drop into oil and cooling channels.

Check dowel sleeves for damage and correct installation position.

Apply permanently elastic sealing compound Drei Bond 1209 to joints to timing case cover. Replace cylinder head gasket.

Scheme 45

Scheme 45: Installation

CAUTION

Use cylinder head bolts only once. There must be no oil in the tapped holes of the engine block and the timing case cover. Risk of cracking and distorted tightening values.

Put the cylinder head on.

Apply a light coat of oil to washer contact area and thread of new cylinder head bolts.

Tighten down cylinder head bolts in sequence 1 to 14.

Tightening torque, refer to 11 12 6AZ in ENGINE - TIGHTENING TORQUES .

Note. Use special tool 00 9 120 for torsion angle tightening.

Scheme 46

Install cable holder (1) and screws. Tighten down screws.

Scheme 47

Replace sealing washer for screw (2).

Screw down sliding rail (1) with screw (2).

Scheme 48

Check dowel sleeves (1) for damage and correct installation position.

Replace sealing ring (2).

Scheme 49

Install thrust bearing flange (1).

Install and tighten down screws.

Scheme 50

Replace O-ring on pipe (3). Install pipe (3).

Install belt pulley (2).

Replace O-ring between thermostat housing (1) and water pump.

Replace O-ring between thermostat housing (1) and return pipe. Install thermostat housing (1) with thermostat.

Scheme 51

CAUTION

It is very easy for the adjustment plates to fall down.

Raise rocker arm.

Note. Special tool 11 4 400 is magnetic.

Install all adjustment plates with special tool 11 4 400.

Scheme 52

Install camshafts. Refer to 11 31 019 REPLACING CAMSHAFTS (S54) .

Adjust valve clearance. Refer to 11 34 004 ADJUSTING VALVE CLEARANCE (S54) .

Assemble engine.

11 12 101 Replacing Cylinder Head Gasket (S50 S54)

Operation is identical to 11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD (S54) .

11 12 503 Disassembling And Assembling Cylinder Head - Cylinder Head Removed (S54)

Special Tools Required

00 1 490
11 0 192
11 0 342
11 0 343
11 0 345
11 1 045
11 1 065
11 1 067
11 1 071
11 3 411
11 3 412

Provide special tools for removing valve springs.

Secure special tool 11 1 065 to special tool 00 1 490.

Scheme 53

Special tool 11 1 071
Special tool 11 1 067
Special tool 11 0 192
Special tool 11 1 045
Special tool 11 0 345
Special tool 11 0 342
Special tool 11 0 343
Special tool 11 3 411

Secure special tool 11 3 411 with special tool 11 1 045 in special tool 11 1 065.

Assemble special tools.

Scheme 54

Secure cylinder head to special tool 11 1 065.

Note. Secure cylinder head from below through locating board with special tool 11 3 412 in spark plug threads.

Scheme 55

Remove coolant pipe (1).

Installation

Scheme 56

Clean sealing surface.
Replace O-rings.

Release bearing pin (1) for tensioning rail (2).

Remove tensioning rail (2).

Installation

Scheme 57

Replace sealing ring.
Tightening torque of bearing pin (1) 13 N.m.

Remove exhaust and inlet rocker arm shafts. Refer to 11 33 545 REMOVING AND INSTALLING/REPLACING ROCKER ARM SHAFT (S54) .

Remove all valve springs. Refer to 11 34 715 REPLACING ALL VALVE SEALS - CYLINDER HEAD REMOVED (S54) .

Replace all stem seals. Refer to 11 34 560 REPLACING ALL VALVE STEM SEALS - CYLINDER HEAD REMOVED (S50 / S54) .

Remove all valves. Refer to 11 34 552 REMOVING AND INSTALLING OR REPLACING ALL VALVES - CYLINDER HEAD REMOVED (S54) .

11 12 527 Remachining A Valve Seat - Cylinder Head Disassembled (S50/S54)

Machine valve seat surface with special tool 00 3 520 or with 00 3 580 in accordance with tool manufacturer's instructions.

Scheme 58

Scheme 58: 11 12 527 Remachining A Valve Seat - Cylinder Head Disassembled (S50/S54)

Note. After machining valve-seat surface: Remachine outside and inside diameters with correction milling tool to the) specified diameters until you obtain valve seat width (5).

Scheme 59

Valve-seat angle.
Correction angle, outside.
Correction angle, inside.
Outside diameter of seat face.
Valve-seat width. Items (1) to (5). Refer to «ENGINE - TECHNICAL DATA»(ref-201329) .

11 12 595 Checking A Valve Guide For Wear - Valve Removed (S50/S54)

Measure tilt clearance.

For measurement, install a new valve in such a way that the end of the valve shaft seals the valve guide.

Mount dial gauge and measure tilt clearance.

Max. permissible tilt clearance, refer to ENGINE - TECHNICAL DATA .

Scheme 60

Scheme 60: 11 12 595 Checking A Valve Guide For Wear - Valve Removed (S50/S54)

CAUTION

Repair valves of larger stem diameters are "not" supplied.

In event of excessive tilt clearance: replace cylinder head.

11 12 729 Checking Cylinder Head For Leaks - Cylinder Head Removed (S54)

Special Tools Required

11 1 402
11 1 404
11 1 431
11 1 433

Seal off coolant openings with following special tools.

Scheme 61

Special tool 11 1 431
Special tool 11 1 433
Special tool 11 1 402
Special tool 11 1 404

Connect compressed air supply to special tool 11 1 404.

Immerse cylinder head in a water bath.

Test pressure: 4.5 bar.

Check cylinder head for escaping air (cracks).

Note. If necessary, soften the bath water with a cleaning agent.

Scheme 62

11 13 000 Removing And Installing, Sealing Or Replacing Oil Sump (S54)

Note. To remove the oil sump, you must lower the front axle support. There is no need to perform a front axle alignment check.

Fit special tool 00 0 200 to special tool 00 0 201 / 202 / 204 / 208 and attach.

Secure special tool 00 0 200 to the front suspension lug on the engine.

Note. The supports (1) of special tool 00 0 208 must rest on the bolt connection of both side walls.

Scheme 63

Scheme 63: 11 13 000 Removing And Installing, Sealing Or Replacing Oil Sump (S54)

Tighten the screws (1 and 2).

Scheme 64

CAUTION

Do not damage fan cowl. If necessary, release fan cowl and remove fan with fan clutch.

Raise engine with special tool 00 0 200 approx. 10 mm.

Scheme 65

Remove suction-filter housing. Refer to 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING (S54) .

Detach guide tube (1) for oil dipstick from intake air manifold.

Scheme 66

Remove engine splash guard.

Remove reinforcement plate.

CAUTION

The article 51 71 374 REMOVING AND INSTALLING / REPLACING REINFORCEMENT PLATE ON FRONT AXLE SUPPORT (M3) contains important installation instructions.

Drain engine oil. Refer to 00 00 250 BMW ENGINE OIL SERVICE INCL. SUPPLEMENTARY SERVICE (S54) .

Unfasten nut. Unscrew holder (1).

Press side locks and detach condensate return (2).

Open cable holder (3).

Installation

Replace O-ring. Insert O-ring and washer in oil sump.

Scheme 67

Unfasten steering spindle from steering gear. Refer to POWER STEERING GEAR .

Detach oil lines from vane pump bracket.

Remove drive belt from belt pulley of power steering vane pump. See POWER STEERING VANE PUMP (M52/M54)

Remove vane pump for power steering. See POWER STEERING VANE PUMP (M52/M54)

Note. Lines remain connected.

Disconnect plug connection to oil level sensor.

Disconnect plug connection to level sensor.

Loosen top and unfasten bottom of left and right engine mounts.

Scheme 68

Detach brackets for left and right control arms from engine carrier. Release retaining brackets for left and right stabilizer bars.

Support front axle support with special tool 31 2 220 in conjunction with special tool 00 2 030.

Release front axle support bolt connection and lower front axle support approx. 100 mm.

These operations are described in DRIVE AXLE SHAFTS & SEAL (FRONT, ALL WHEEL DRIVE) .

Scheme 69

Note. There is no need to detach the steering gear from the front axle support.

Detach return hose (1) of oil separator from oil sump.

CAUTION

A residual amount of oil will emerge after the screws on the cover (2) are released. Have cleaning cloths and container ready.

Remove cover (2) from oil sump.

Scheme 70

Installation

Replace gasket on cover (2).

Unfasten oil sump screws at transmission and engine ends.

CAUTION

A residual amount of oil remains in front section of oil sump. Have cleaning cloths and container ready.

Lower and remove oil sump.

Scheme 71

Installation

Sealing faces clean and free of seal debris. Check seal, replace if necessary.
Apply Drei Bond 1209 sealing compound to area around joint: approx. 3 mm wide and 2 mm high.

Installation

Install oil sump.
Install all oil pan screws.
Insert screws in transmission end without preload at this stage.
Tighten down screws in engine end.
Tighten down screws in transmission end.

11 14 110 Removing And Installing, Sealing Or Replacing Timing Case Cover (S50 / S54)

Special Tools Required

00 0 200

Note. Illustrations show the S50. The procedure is identical for the S54.

Unscrew oil sump. Refer to 11 13 000 REMOVING AND INSTALLING, SEALING OR REPLACING OIL SUMP (S54) .

Note. After removing oil sump, reinstall front axle support provisionally and remove special tool 00 0 200.

Remove cylinder head. Refer to 11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD (S54) .

Remove vibration damper. Refer to 11 23 010 REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER (S54) .

Remove radial seal. Refer to 11 14 141 REPLACING RADIAL SEAL IN LOWER TIMING CASE COVER (S50 / S54) .

Note. Install new radial seal only after installing timing case cover.

Remove vane pump from timing case cover (lines remain connected).

Unfasten screws and remove timing case cover.

Scheme 72

Note. Dowel pins for location purposes are pressed into the timing case cover.

Installation

Keep sealing faces clean and free of oil. Check dowel pins for damage and correct installation position.
Replace seals.
Apply a thin coat of Drei Bond 1209 sealing compound to ends of seals at front and rear.
Position seals on dowel pins in timing case cover.

Installation

Fit timing case cover with seals, insert all screws and pretighten to approx. 5 N.m.
Fully tighten all screws in alternate sequence.
Tightening torque, refer to 11 14 1AZ in «ENGINE - TIGHTENING TORQUES»(ref-201358) .

CAUTION

Once all screws have been tightened down, retighten them in a second operation.

Scheme 73

Replace radial sealing ring. Refer to 11 14 141 REPLACING RADIAL SEAL IN LOWER TIMING CASE COVER (S50 / S54) .

Assemble engine.

11 14 141 Replacing Radial Seal In Lower Timing Case Cover (S50/S54)

Special Tools Required

11 1 220
11 2 380
11 2 384
11 5 090
11 7 240

Remove vibration damper. Refer to 11 23 010 REMOVING AND INSTALLING/REPLACING VIBRATION DAMPER (S54) .

Note. Illustrations show the S54.

The special tools and the actual procedure are identical for the S50.

Removal

Fit special tool 11 2 384 on crankshaft.

Scheme 74

Screw in special tool 11 2 380 until it is firmly connected to the radial seal.

Remove radial seal by tightening in the screw.

Scheme 75

Installation

CAUTION

Do not touch sealing lip of new radial seal with your fingers.

Fit special tool 11 7 240 on sprocket wheel.

Oil sealing lips of new radial seal (1).

Push radial seal (1) over special tool 11 7 240 until it rests against timing case cover.

Remove special tool 11 7 240.

Scheme 76

CAUTION

Do not touch sealing lip of new radial seal (1) when installing special tool 11 5 090.

Install special tool 11 5 090 and tighten down.

Scheme 77

Draw in new radial seal with special tool 11 1 220 until it is flush with timing case cover.

Scheme 78

11 14 151 Replacing Crankshaft Radial Seal (Transmission Side)

Note. This repair instruction is valid for the following engines: M40 / M42 / M43 / M43TU / M44 M50 / M52 / M52TU / M54 / M56 S52/S54

Necessary Preliminary Tasks

Remove gearbox.
Drain off engine oil.
Remove flywheel. See «11 22 500 Removing And Installing Or Replacing Flywheel (M52/S52/M52TU/M54/S54)»(/bmw/m3/e46-1999-2006/remont/mechanical/#engine-repair-s54__11-22-500-removing-and-installing)

Unfasten oil sump screws on transmission end. Loosen oil pan.

Scheme 79

Release screws in end cover at rear.

Carefully detach oil sump gasket from end cover, remove end cover.

Note. After removing end cover: check oil sump gasket for damage. If necessary, remove oil sump and replace oil sump gasket.

Scheme 80

Note. As from 4/98, a new type of radial seal is used in the Series and as a replacement. This radial seal may only be supported with a "support bushing".

Note. If the radial seal is supported without the support bushing (1) for more than six months, operational reliability will no longer be assured and the radial seal must not be used any further.

Scheme 81

Distinguishing feature

(1) New version "without hose spring".
(2) Old version "with hose spring".

IMPORTANT

The sealing lip of the new version (1) is very sensitive and must not be kinked under any circumstances. Do not touch the sealing lip with your fingers.

Scheme 82

Note. The end cover is offered in the kit with a radial seal.

If necessary, lift out the radial sealing ring and drive in new sealing ring using special tool 11 1 260 in conjunction with special tool 00 5 500.

Scheme 83

Check dowel sleeves (1) for damage and correct installation position.

Replace seal (2).

Apply thin, uniform coat of Drei Bond 1209 sealing compound to edges of joint on oil pan.

Scheme 84

IMPORTANT

Do not use special tool 11 2 213 for the new radial seal version.

Scheme 85

Note. When fitting the end cover with radial seal on the crankshaft, it is only permitted to use the "support bushing (1)" as an installation tool.

Lubricate contact face of crankshaft.

Scheme 86

IMPORTANT

Push on end cover with support bushing (1) straight and without tilting sideways.

Note. Screw threads (1) are coated with sealing compound.

Replace screws (1).

Insert all screws and tighten down end cover.

Scheme 87

Note. Keep the support bushing (1) of the new radial seal version as a "special tool", then render the special tool 11 2 213 unusable and dispose of it.

The old and new radial seal versions can be installed with the support bushing (1).

Scheme 88

11 21 500 Replacing Crankshaft (S54)

(Engine removed)
Remove cylinder head. Refer to «11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD (S54)»(/bmw/m3/e46-1999-2006/remont/mechanical/#engine-repair-s54__11-12-100-removing-and-installingsealing) .
Remove lower timing case cover.
Remove pistons. Refer to «11 25 530 REMOVING AND 530 INSTALLING/REPLACING ALL PISTONS (S54)»(/bmw/m3/e46-1999-2006/remont/mechanical/#engine-repair-s54__11-25-530-removing-and-installingreplacing) .

Remove flywheel. See 11 22 500 Removing And Installing Or Replacing Flywheel (M52/S52/M52TU/M54/S54)

Remove end cover at rear. This task is described in the article "Replacing crankshaft radial seal".

Checking axial clearance

If permitted end float is exceeded, check crankshaft, guide bearing shells and engine block, replacing if necessary. Refer to ENGINE - TECHNICAL DATA .

Scheme 89

Holders for oil lines are fitted on main bearing caps 3 and 5.

CAUTION

Holders (1 and 2) are different.

Holder (1) with elongated hole in vertical direction.

Holder (2) with elongated hole in horizontal direction.

Scheme 90

Note. Main bearing caps 1 to 5 are marked on exhaust side.

Main bearing caps 6 and 7 are not marked.

Main bearing cap 6 is guide bearing.

Remove screws securing main bearing caps.

Remove main bearing caps 1 to 7.

Lever out crankshaft.

Scheme 91

CAUTION

The increment gear cannot be released without the screws being damaged or destroyed.

A crankshaft with fitted increment gear is available. If in an exceptional case increment gear has to be removed

CAUTION

Protect crankshaft against damage.

Release screws, drill out screw heads if necessary.

Scheme 92

Installation

Replace increment gear and screws.

Tighten down screws to 5 N.m.

Mark 45° angle on screw head and sensor gear.

CAUTION

Screws can be tightened down to max. 45°.

Tighten down with 40° to 45° torsion angle.

Scheme 93

If necessary, remove sprocket wheel

Release screw in bore (1).

Detach sprocket wheel from crankshaft.

Scheme 94

Note. Sprocket wheel is secured with an adapter sleeve (1) to crankshaft.

Installation

Scheme 95

Check adapter sleeve (1) for damage and correct installation position.

Installation

Align adapter sleeve of sprocket wheel to locating bore of crankshaft and fit sprocket wheel.
Apply a thin coat of screw retaining compound to screw thread (1).

Insert screw.

Tighten down crankshaft sprocket wheel to 10 N.m.

Scheme 96

CAUTION

Observe grinding stage of crankshaft. Refer to ENGINE - TECHNICAL DATA .

Replace main crankshaft bearing shells. Refer to 11 21 531 REPLACING ALL CRANKSHAFT MAIN BEARING SHELLS (S54) .

Replace conrod bearing shells. Refer to 11 24 571 REPLACING ALL CONROD BEARINGS (S54) .

Replace grooved ball bearings in crankshaft. Refer to 11 21 571 REPLACING GROOVED BALL BEARING IN CRANKSHAFT (M52 / S52 / M52TU / M54 / S50 / S54) .

11 21 531 Replacing All Crankshaft Main Bearing Shells (S54)

Special Tools Required

00 2 590
00 9 120

(Engine dismantled)

The preliminary operations are described in 11 21 500 REPLACING CRANKSHAFT (S54) .

Note. Piston cooling spray nozzles are installed between the bearing seats.

Check spray nozzles for damage.

Scheme 97

Note. Install bearing shells with continuous lubricant groove and one retaining lug in engine block. Fit bearing shells without continuous lubricant groove and two retaining lugs in bearing cover.

Scheme 98

Installation

When the bearing shells or the crankshaft are replaced, the classification for bearing shell arrangement in the engine block is eliminated.
Only install yellow bearing shells in the engine block.

Note. The axial guide on the crankshaft is fitted to bearing point 6.

Insert pilot bearing shell in the engine block.

Scheme 99

Note. The crankshaft is marked with yellow, green or white paint according to the tolerance of the main journal.

Insert crankshaft in engine block.

Scheme 100

Installation

Scheme 101

The bearing shell classification for the bearing cover is marked on the crankshaft in yellow, green or white paint.
Place main bearing shells with same color code as that of crankshaft in main bearing caps.

The bearing shells are marked with yellow, green or white paint.

Scheme 102

Bearing shell.
Guide bearing. Observe grinding stage of main bearing journals. Refer to «ENGINE - TECHNICAL DATA»(ref-201329) .

Note. Main bearing caps 1 to 5 are marked on exhaust side. Main bearing caps 6 and 7 are not marked. Main bearing cap 6 is thrust bearing.

Scheme 103

Check clearance on main crankshaft bearing.

Install crankshaft and place special tool 00 2 590 (Plastigage Type PG1) on oil-free crankshaft.

Do not twist crankshaft.

Scheme 104

Insert main bearing caps in such a way that guide grooves of main bearing shells lie on one side.

Align main bearing cap flush with side of bearing seat.

Scheme 105

Installation

To check main bearing clearance, use the old main bearing screws.

There must be no oil in the blind holes (risk of cracking).

Note. Wash and oil main bearing bolts.

Scheme 106

Tighten down main bearing screws with jointing torque.
Tighten down main bearing screws using special tool 00 9 120 and torsion angle. Tightening torque, refer to 11 11 1AZ in «ENGINE - TIGHTENING TORQUES»(ref-201358) .

Remove main bearing cap and read off bearing clearance at width of pinched plastic thread on measuring scale.

Crankshaft bearing clearance radial, refer to ENGINE - TECHNICAL DATA .

If necessary, fit new bearing shells with a different color code to correct bearing clearance.

Scheme 107

Note. Remove plastic thread. Coat main bearing shells and crankshaft with engine oil.

Insert main bearing cap in such a way that grooves of main bearing shell guide lie on one side.

Align main bearing cap flush with side of bearing seat.

Scheme 108

Installation

Always replace screws of main bearing caps with new ones.
There must be no oil in the blind holes (risk of cracking).

Note. Wash and oil main bearing bolts.

Holders for oil lines are fitted on main bearing caps 3 and 5.

CAUTION

Holders (1 and 2) are different.

Holder (1) with elongated hole in vertical direction.

Holder (2) with elongated hole in horizontal direction.

Scheme 109

Tightening specifications for main bearing

Tighten all screws on main bearing cover with jointing torque.
Unfasten screws on main bearing cover 6.
Strike back and front of crankshaft with plastic hammer to center thrust bearing (do not damage crankshaft).
Tighten screws of main bearing cover 6 with jointing torque.
Tighten down all screws on main bearing caps with special tool 00 9 120 and torsion angle.

Tightening torque, refer to 11 11 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 110

Check axial play.

If permitted end float is exceeded, check crankshaft, guide bearing shells and engine block, replacing if necessary. Refer to ENGINE - TECHNICAL DATA .

Scheme 111

11 21 571 Replacing Grooved Ball Bearing In Crankshaft (M52/S52/M52TU/M54/S50/S54)

Special Tools Required

00 5 500
11 2 340
11 2 350

(Clutch removed)

IMPORTANT

In version with needle bearing (1) in dual-mass flywheel (2), no grooved ball bearing may be fitted in the crankshaft.

Scheme 112

Version With Grooved Ball Bearing

Remove guide bearing with special tool 11 2 340.

Scheme 113

Install new thrust bearing and drive firmly home with special tool 11 2 350 in conjunction with special tool 00 5 500.

Scheme 114

11 22 500 Removing And Installing Or Replacing Flywheel (M52/S52/M52TU/M54/S54)

Special Tools Required

11 2 170

(Clutch removed)

Lock flywheel with special tool 11 2 170.

Scheme 115

Unfasten screws and remove flywheel.

Scheme 116

Installation

Scheme 117

Check dowel sleeve for damage and correct installation position.

Installation

Scheme 118

Position of dowel sleeve (1) in dual-mass flywheel is identified by two notches next to associated bolt hole.

Installation

Scheme 119

Clean thread and install new micro-encapsulated screws.
Tightening torque, refer to 11 22 1AZ in «ENGINE - TIGHTENING TORQUES»(ref-201358) .

11 23 010 Removing And Installing/Replacing Vibration Damper (S54)

Special Tools Required

00 9 120
11 0 280

Remove engine underguard.

Remove fan cowl. Refer to 17 11 031 REPLACING FAN COWL (S54) .

Remove A/C compressor drive belt. Refer to 11 28 050 REPLACING A/C COMPRESSOR DRIVE BELT (S54) .

Remove alternator drive belt. Refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT (S54) .

Unfasten screws.

Remove plate (1) for TDC marking.

Scheme 120

Unfasten screws. Remove belt pulley.

Scheme 121

Mount special tool 11 0 280 on vibration damper.

Note. Special tool 11 0 280 is supported on mounting bracket for A/C system.

CAUTION

Do not damage mounting bracket for A/C system.

Loosen screws (1).

Remove special tool 11 0 280.

Scheme 122

CAUTION

Do not damage belt pulley of water pump.

Remove vibration damper from crankshaft and feed out below belt pulley of water pump.

Scheme 123

Installation

Align locating bore in vibration damper to dowel pin (1).

Scheme 124

CAUTION

Feed in vibration damper (1) behind belt pulley (2) of water pump.

Scheme 125

Installation

Attach vibration damper and align to dowel pin.

Note. A washer is installed under screws (1).

Replace screws (1).

Note. Feed in special tool 11 0 280 behind tensioning roller and support on mounting bracket of A/C system.

Scheme 126

Mount special tool 11 0 280 on vibration damper.

Installation

Tighten down screws on vibration damper with special tool 00 9 120.

Tightening torque, refer to 11 23 2AZ in ENGINE - TIGHTENING TORQUES .

Scheme 127

Installation

Scheme 128

Install belt pulley.
Tighten down screws.
Tightening torque, refer to 11 23 3AZ in «ENGINE - TIGHTENING TORQUES»(ref-201358) .

Installation

Check dowel sleeves (1) for damage and correct installation

Scheme 129

Installation

Install plate (1) for TDC marking.

Scheme 130

11 24 571 Replacing All Conrod Bearings (S54)

(Piston removed)

CAUTION

The S54 engine has two types of conrod with different conrod bolts.

Differentiating Features

Scheme 131

Conrod bolt with M11x1.25 thread. Bolt head: bihexagonal 12 mm A/F.
Conrod bolt with M10x1.25 thread. Bolt head: Torx E12.

CAUTION

The procedure for replacing the conrod bolts and the tightening specifications are different. Mixing up the procedure for replacing the conrods and conrod bolts and the tightening specifications will result in serious engine damage.

CAUTION

Note grinding stages on crankshaft. Refer to ENGINE - TECHNICAL DATA .

Note. Classified conrod bearing shells color-coded "Yellow and Green" are installed in the model series.

The classification is removed when the conrod bearing shells are replaced.

Scheme 132

Install conrod bearing shells (1) color-coded "Blue" in conrod at top.
Install conrod bearing shells (2) color-coded "Red" in conrod at top. Install piston. Refer to «11 25 530 REMOVING AND 530 INSTALLING/REPLACING ALL PISTONS (S54)»(/bmw/m3/e46-1999-2006/remont/mechanical/#engine-repair-s54__11-25-530-removing-and-installingreplacing) .

11 25 530 Removing And Installing/Replacing All Pistons (S54)

(Engine removed)

Fit engine to special tool 00 1 450.

Removing cylinder head.
Removing oil pan.
Removing oil pump.

CAUTION

Re-install piston, conrod and bearing shells back in the same position and in the same installation location. Conrod and conrod bearing cover are designated with same pair number: do not interchange/confuse.

In event of heavy oil carbon residue: Carefully remove oil carbon residue from cylinder wall.

Scheme 133

Note. Piston cooling spray nozzles are installed between the bearing seats.

Check spray nozzles for damage. If necessary, remove piston-cooling spray nozzles.

Scheme 134

CAUTION

The S54 engine has two types of conrod with different conrod bolts.

Differentiating Features

Scheme 135

Conrod bolt with M11x1.25 thread. Bolt head: bihexagonal 12 mm A/F.
Conrod bolt with M10x1.25 thread. Bolt head: Torx E12.

CAUTION

Removal And Installation

Removal and installation of pistons and conrods with M11x1.25 conrod bolt and M10x1.25 conrod bolt are described separately.

Remove and install piston (M11x1.25 conrod bolt, refer to 11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (S54 WITH M11X1.25 CONROD BOLT) .

Remove and install piston (M10x1.25 conrod bolt), refer to 11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (S54 WITH M10X1.25 CONROD BOLT) .

11 25 530 Removing And Installing/Replacing All Pistons (S54 With M11X1.25 Conrod Bolt)

Special Tools Required

00 2 590
00 9 120
11 3 480
11 9 120

(Engine removed)

Removal

Removal of pistons is described separately from installation. Assembly sequence for removal and installation is different.

Fit engine to special tool 00 1 450.

Removing cylinder head.
Removing oil pan.
Removing oil pump.

CAUTION

In event of heavy oil carbon residue

Carefully remove oil carbon residue from cylinder wall.

Scheme 136

Note. Piston cooling spray nozzles are installed between the bearing seats.

Check spray nozzles for damage.

If necessary, remove piston-cooling spray nozzles.

Scheme 137

CAUTION

The S54 engine has two types of conrod with different conrod bolts.

Differentiating Features

A Conrod bolt with M11x1.25 thread. Bolt head: bihexagonal 12 mm A/F.
B Conrod bolt with M10x1.25 thread. Bolt head: Torx E12.

The procedure for replacing the conrod bolts and the tightening specifications are different.

Mixing up the procedure for replacing the conrods and conrod bolts and the tightening specifications will result in serious engine damage.

Scheme 138

CAUTION

Contrary to the instructions for all other BMW engines, the conrod bolts must not be replaced in the S54 engine with the M11x1.25 conrod bolt. The M11x1.25 may only be reused in the same conrod thread. Conrods with M11x1.25 conrod bolts are no longer supplied as replacements. If a conrod or a conrod bolt with M11x1.25 thread is damaged: replace the conrods with a complete set of conrods with M10X1.25 Conrod Bolts. .

Scheme 139

Release conrod bolts.
Remove conrod bearing cap.
Set conrod bolts and conrod bear caps down in neat order.

Scheme 140

Insert special tool 11 3 480 in conrod.

Remove connecting rod with piston from cylinder-head side.

Scheme 141

CAUTION

Piston and piston bolts are paired and must not be fitted individually.

Lift out retaining ring and press out piston pin.

Scheme 142

Installation

Installation of pistons is described separately from removal. The assembly sequence for removal and installation is different.

The piston pin must be able to be pressed through the liner by hand with little force and must not display any significant play. If necessary, replace connecting rods.

Scheme 143

Note. Only conrods of the same weight group are allowed to be installed inside an engine. Connecting rods are only suppllied in complete sets.

Prior to installation, measure piston installation clearance: Measure piston diameter with micrometer at measuring point A from bottom edge of piston and offset at 90° to the axis of the piston pin. For measuring point A, refer to 11 25 Pistons With Rings And Pins S54, in ENGINE - TECHNICAL DATA .

Scheme 144

Adjust micrometer to cylinder bore of engine block. Set internal caliper on micrometer to zero. Measure bottom, center and top of cylinder bore in direction of travel and direction of engine rotation.

Scheme 145

Diameter of cylinder bore, refer to 11 00 Engine In General S54 in «ENGINE - TECHNICAL DATA»(ref-201329) .
Piston installation clearance, refer to 11 25 Pistons With Rings And Pins S54 in «ENGINE - TECHNICAL DATA»(ref-201329) .
Permitted total wear clearance, refer to 11 25 Pistons With Rings And Pins S54 in «ENGINE - TECHNICAL DATA»(ref-201329) .

CAUTION

Piston and piston pins are paired and must not be fitted individually.

Fit conrod with piston pin to piston in such a way that both of the visible pair numbers on the installation direction arrow on the piston point to the right.

Scheme 146

Install retaining ring.

Scheme 147

CAUTION

Note grinding stages on crankshaft. Refer to 11 21 Crankshaft And Bearings S54 in ENGINE - TECHNICAL DATA .

Note. Classified conrod bearing shells color-coded "Yellow and Green" are installed in the model series. The classification is removed when the conrod bearing shells are replaced.

Install conrod bearing shells (1) color-coded "Blue" in conrod at top.
Install conrod bearing shells (2) color-coded "Red" in conrod at top.

Scheme 148

Insert special tool 11 3 480 in conrod.

Scheme 149

Lightly coat pistons and piston rings with oil.

Offset the contact points of the piston rings by approx. 120° to each other but do not position above the piston pin boss.

Compress piston rings with special tool 11 9 120.

Scheme 150

Keep piston rings pressed with special tool 11 9 120. Install piston so that arrow points to camshaft drive.

Scheme 151

CAUTION

Danger of piston ring failure. Only press pistons into place with finger force - do not knock in!

Attach crankpin to connecting rod.

Remove special tool 11 3 480.

Check connecting rod bearing clearance: Piston in BDC position. Fit special tool 00 2 590 (Plastigage Type PG 1) to the oil-free crankshaft.

Scheme 152

Fit bearing caps so that pair numbers match up.

Scheme 153

Conrod With M11X1.25 Conrod Bolt

CAUTION

Conrod With M11X1.25 Conrod Bolt

CAUTION

Do not distort conrods or crankshaft

Tighten down conrod bolts with special tool 00 9 120.

Tightening torque

Application torque 5 N.m.
Joining torque 30 N.m.
Angle of rotation 70°.

Scheme 154

Remove bearing cap and read off bearing play at width of flattened plastic thread with assistance of measurement scale.

Conrod Bearing Clearance: 0.030 To 0.070 mm.

CAUTION

If a bearing clearance of below 0.030 mm is measured: Replace Conrod Bearing Shells.

If a bearing clearance of below 0.030 mm is measured with the new conrod bearing shells

Replace the conrods with a complete set of conrods with M10X1.25 Conrod Bolts.

Scheme 155

Remove plastic thread.
Coat crankshaft and bearing shells with oil.
Fit bearing caps so that the pair numbers match up.

CAUTION

The M11x1.25 may only be reused in the same conrod thread.

Insert conrod bolts.

Conrod With M11X1.25 Conrod Bolt

Tighten down conrod bolts with special tool 00 9 120.

CAUTION

The tightening torque only applies to conrod bolts with M11x1.25 threads.

Tightening torque

Application torque 5 N.m.
Joining torque 30 N.m.
Angle of rotation 70°.

Install spray nozzles for piston cooling, tighten down screw.

Tightening torque, 11 11 7AZ. Refer to ENGINE - TIGHTENING TORQUES .

11 25 530 Removing And Installing/Replacing All Pistons (S54 with M10x1.25 Conrod Bolt)

Special Tools Required

00 2 590
00 9 120
11 2 050
11 9 120

(Engine removed)

Removal

Removal of pistons is described separately from installation. Assembly sequence for removal and installation is different.

Fit engine to special tool 00 1 450.

Removing cylinder head.
Removing oil pan.
Removing oil pump.

CAUTION

In event of heavy oil carbon residue

Carefully remove oil carbon residue from cylinder wall.

Note. Piston cooling spray nozzles are installed between the bearing seats.

Check spray nozzles for damage.

If necessary, remove piston-cooling spray nozzles.

CAUTION

The S54 engine has two types of conrod with different conrod bolts.

Differentiating Features

A Conrod bolt with M11x1.25 thread. Bolt head: bihexagonal 12 mm A/F.
B Conrod bolt with M10x1.25 thread. Bolt head: Torx E12.

The procedure for replacing the conrod bolts and the tightening specifications are different.

Mixing up the procedure for replacing the conrods and conrod bolts and the tightening specifications will result in serious engine damage.

CAUTION

In the S54 engine with the M10x1.25 conrod bolt (B) the conrod bolts must be replaced.

Conrod bolts (B) are made from a material which only reaches its maximum tensile strength after they have been tightened three times.

Connecting rod bolts (B) must be tightened at least three times but no more than five times.

Scheme 156

Release conrod bolts.
Remove conrod bearing cap.
Set conrod bolts and conrod bear caps down in neat order.

Insert special tool 11 2 050 in conrod.

Remove connecting rod with piston from cylinder-head side.

Scheme 157

CAUTION

Piston and piston bolts are paired and must not be fitted individually.

Lift out retaining ring and press out piston pin.

Installation

Installation of pistons is described separately from removal. The assembly sequence for removal and installation is different.

The piston pin must be able to be pressed through the liner by hand with little force and must not display any significant play. If necessary, replace connecting rods.

Note. Only conrods of the same weight group are allowed to be installed inside an engine. Connecting rods are only supplied in complete sets.

Diameter of cylinder bore, refer to 11 00 Engine In General S54 in «ENGINE - TECHNICAL DATA»(ref-201329) .
Piston installation clearance, refer to 11 25 Pistons With Rings And Pins S54 in «ENGINE - TECHNICAL DATA»(ref-201329) .
Permitted total wear clearance, refer to 11 25 Pistons With Rings And Pins S54 in «ENGINE - TECHNICAL DATA»(ref-201329) .

CAUTION

Piston and piston pins are paired and must not be fitted individually.

Fit conrod with piston pin to piston in such a way that both of the visible pair numbers on the installation direction arrow on the piston point to the right.

Install retaining ring.

CAUTION

Note grinding stages on crankshaft. Refer to 11 21 Crankshaft And Bearings S54 in ENGINE - TECHNICAL DATA .

Note. Classified conrod bearing shells color-coded "Yellow and Green" are installed in the model series. The classification is removed when the conrod bearing shells are replaced.

Install conrod bearing shells (1) color-coded "Blue" in conrod at top.
Install conrod bearing shells (2) color-coded "Red" in conrod at top.

Insert special tool 11 2 050 in conrod.

Lightly coat pistons and piston rings with oil.

Offset the contact points of the piston rings by approx. 120° to each other but do not position above the piston pin boss.

Compress piston rings with special tool 11 9 120.

Keep piston rings pressed with special tool 11 9 120. Install piston so that arrow points to camshaft drive.

CAUTION

Danger of piston ring failure. Only press pistons into place with finger force - do not knock in!

Attach crankpin to connecting rod.

Remove special tool 11 2 050.

Conrod With M10X1.25 Conrod Bolt

CAUTION

Conrod bolts (B) are made from a material which only reaches its maximum tensile strength after they have been tightened three times. Connecting rod bolts (B) must be tightened at least three times but no more than five times. The tightening specifications detailed in the following must be observed exactly. Mixing up the procedure for replacing the conrods and conrod bolts and the tightening specifications will result in serious engine damage.

Check connecting rod bearing clearance

Piston in BDC position.

Fit special tool 00 2 590 (Plastigage Type PG 1) to the oil-free crankshaft.

Fit bearing caps so that pair numbers match up.

Conrod With M10X1.25 Conrod Bolt

If A New Set Of Conrods Has Been Installed

Use the conrod bolts used in the new set of conrods.

If The Conrods Already Used Have Been Installed

Install new conrod bolts.

Conrod With M10X1.25 Conrod Bolt

CAUTION

Do not distort conrods or crankshaft.

First Tightening Of Conrod Bolts

Tighten down conrod bolts with special tool 00 9 120.

Tightening torque

Application torque 5 N.m.
Joining torque 30 N.m.
Angle of rotation 105°.

Remove bearing cap and read off bearing play at width of flattened plastic thread with assistance of measurement scale.

Conrod Bearing Clearance: 0.030 To 0.070 mm.

Remove plastic thread.
Coat crankshaft and bearing shells with oil.
Fit bearing caps so that the pair numbers match up.
Fit the conrod bolts used for the bearing clearance.

Conrod With M10X1.25 Conrod Bolt

Second Tightening Of Conrod Bolts

Tighten down conrod bolts with special tool 00 9 120.

Tightening torque

Application torque 5 N.m.
Joining torque 30 N.m.
Angle of rotation 105°.

CAUTION

The following work step differs depending on whether a new set of conrods has been fitted or only the conrod bolts have been replaced. If A New Set Of Conrods Has Been Installed: The conrod bolts must not be tightened down again as they have already been screwed down three times when the conrod was machined and have reached their maximum tensile strength. If The Conrods Are Reused And Only The Conrod Bolts Have Been Replaced: The conrod bolts must be slackened again and brought to maximum tensile strength by the third tightening operation. If the conrod bolts have not been tightened at least three times or have been tightened more than five times, this will result in serious engine damage.

If necessary, back off conrod bolts by approx. one turn.

Third Tightening Of Conrod Bolts

Tighten down conrod bolts with special tool 00 9 120.

Tightening torque

Application torque 5 N.m.
Joining torque 30 N.m.
Angle of rotation 105°.

Install spray nozzles for piston cooling, tighten down screw.

Tightening torque, 11 11 7AZ. Refer to ENGINE - TIGHTENING TORQUES .

11 25 671 Replacing Piston Rings On All Pistons (S62/S54)

(Piston removed)

Remove piston rings with piston-ring compressing pliers.

Note. It might not be possible to find the identification on used piston rings. Put aside piston rings in correct sequence and installation position.

Scheme 158

Scheme 158: 11 25 671 Replacing Piston Rings On All Pistons (S62/S54)

Installation

Insert piston rings with the word "TOP" facing piston crown.

Plain compression ring "TOP".
Tapered compression ring "TOP".
Slotted oil-scraper ring with rubber-lined spring.

Offset the contact points of the piston rings by approx. 120° to each other but do not position above the piston pin boss.

Scheme 159

Measure axial play.

Axial clearance, refer to ENGINE - TECHNICAL DATA .

Scheme 160

Measure end clearance.

End clearance, refer to ENGINE - TECHNICAL DATA .

Scheme 161

11 28 010 Replacing alternator drive belt (S54)

Note. If the drive belt is to be subsequently reused: Mark direction of travel and reinstall drive belt in same direction of travel.

Remove fan clutch with fan impeller. Refer to 11 52 020 REMOVING AND INSTALLING/REPLACING FAN CLUTCH (S52 / S54 / M52 / M52TU / M54 / M56) .

Remove A/C compressor drive belt. Refer to 11 28 050 REPLACING A/C COMPRESSOR DRIVE BELT (S54) .

Place on screw connection of tensioning wheel and compress belt tensioner slowly and carefully.

Hold belt tensioner under tension, remove drive belt.

CAUTION

If contaminated with hydraulic fluid: Replace drive belt.

Installation

Check drive belt for coolant and oil residue and replace if necessary.

Scheme 162

Installation

Fit drive belt and check if it is correctly located on pulleys.

Scheme 163

11 28 050 Replacing A/C Compressor Drive Belt (S54)

Note. If the drive belt is to be subsequently reused: Mark direction of travel and reinstall drive belt in same direction of travel. Remove engine splash guard.

Push back belt tensioner at hexagon head and remove drive belt.

CAUTION

If contaminated with hydraulic fluid: Replace drive belt.

Installation

Check drive belt for coolant and oil residue and replace if necessary.

Scheme 164

Installation

Fit drive belt and check if it is correctly located on pulleys.

Scheme 165

11 31 005 Checking Camshaft Timing (S54)

Special Tools Required

11 2 300
11 5 100
11 7 130
11 9 140
12 6 050
12 6 410
12 6 411

Remove fan clutch with fan cowl. Refer to 11 52 020 REMOVING AND INSTALLING/REPLACING FAN CLUTCH (S52 / S54 / M52 / M52TU / M54 / M56) .

Remove cylinder head cover. Refer to 11 12 000 REMOVING AND INSTALLING, SEALING CYLINDER HEAD COVER (S54) .

Remove all spark plugs.

When the engine is switched off, VANOS moves the camshafts to a position which is advantageous to engine starting.

CAUTION

The timing must "not" be checked in this position. The camshafts must first be turned back to their initial position.

Attach special tool 11 5 100 to four screws of crankshaft hub.

Scheme 166

Rotate crankshaft in direction of rotation as far as firing TDC position of 1st cylinder.

Scheme 167

CAUTION

Do not turn the engine back.

Rotate crankshaft in direction of rotation as far as ignition TDC-J position of cylinder 1. Secure vibration damper in position with special tool 11 2 300.

Scheme 168

Detach bracket of oil line from timing case cover.

Scheme 169

Remove oil line from VANOS adjustment unit.

Scheme 170

Fit special tool 11 7 130 to VANOS adjustment unit.

Connect compressed air (2 to 8 bar).

Scheme 171

Disconnect plug connection on solenoid valve.

Scheme 172

Connect special tool 12 6 050 in conjunction with special tool 12 6 411 (from special tool kit 12 6 410) to solenoid valves. Connect special tool 12 6 411 to correct terminals on car battery.

Alternately press toggle switch buttons 1 and 2 several times on special tool 12 6 050.

Scheme 173

Press and hold down toggle switch button 1 on special tool 12 6 050.

At same time, rotate inlet camshaft at hexagon drive against direction of rotation as far as it will go.

Scheme 174

Note. Spline teeth in VANOS gear are engaged; and inlet camshaft cannot be rotated further.

Alternately press toggle switch buttons 3 and 4 several times on special tool 12 6 050.

Scheme 175

Press and hold down toggle switch button 3 on special tool 12 6 050.

At same time, rotate exhaust camshaft at hexagon drive against direction of rotation as far as it will go.

Scheme 176

Note. Spline teeth in VANOS gear are engaged; and exhaust camshaft cannot be rotated further.

Disconnect compressed air from special tool 11 7 130.

Remove special tool 11 7 130.

Scheme 177

Check camshaft setting

Attach special tool 11 9 140 and join in locating bore of inlet camshaft.

Note. The inlet camshaft is correctly adjusted when special tool 11 9 140 rests flat on the cylinder head or protrudes by max. 0.5 mm to the exhaust side.

If the special tool 11 9 140 protrudes to the inlet side, the timing must be readjusted.

Scheme 178

Join special tool 11 9 140 in locating bore of exhaust camshaft.

Note. The exhaust camshaft is correctly adjusted when special tool 11 9 140 rests flat on the cylinder head or protrudes by max. 0.5 mm to the exhaust side.

If the special tool 11 9 140 protrudes to the inlet side, the timing must be readjusted.

If necessary, adjust camshaft timing. Refer to 11 31 505 ADJUSTING CAMSHAFT TIMING (S54) .

Scheme 179

Replace sealing rings of banjo bolt.

Install banjo bolt but do not tighten down yet.

Scheme 180

Install bracket of oil line. Install screw and tighten down.

Scheme 181

Tighten down banjo bolt of oil line.

Tightening torque, refer to 11 36 9AZ in ENGINE - TIGHTENING TORQUES .

Scheme 182

Remove special tool 11 2 300.

Assemble engine.

Scheme 183

CAUTION

There is air in the VANOS system once it is opened. In the first few seconds after startup this results in a clearly discernible "rattling noise". This rattling noise does "not" indicate incorrect assembly. The rattling noise will disappear as soon as the oil pressure has built up and the system has vented.

11 31 019 Replacing Camshafts (S54)

Special Tools Required

11 2 300
11 4 380
11 5 100
11 7 130
11 7 160
11 7 200
11 7 342
11 9 130
11 9 140
11 9 170
12 6 050
12 6 410
12 6 411

Read fault memory and make a documentary record.

Remove cylinder head. Refer to 11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD (S54) .

Remove all spark plugs.

Remove fan clutch with fan impeller and fan cowl. Refer to 11 52 020 REMOVING AND INSTALLING/REPLACING FAN CLUTCH (S52 / S54 / M52 / M52TU / M54 / M56) and 17 11 031 REPLACING FAN COWL (S54) .

Removal

Removal of the VANOS adjustment unit and the camshafts is described separately from installation. The assembly sequence for removal and installation is different.

Fit special tool 11 5 100 to four screws on crankshaft hub.

Scheme 184

Rotate crankshaft in direction of rotation as far as firing TDC position of 1st cylinder.

Scheme 185

Secure vibration damper with special tool 11 2 300 in firing TDC position of 1st cylinder.

Scheme 186

CAUTION

When the engine is switched off, VANOS moves the camshafts to a position which is advantageous to engine starting. The camshafts and the VANOS adjustment unit must be placed in the installation position before the VANOS adjustment unit is removed.

Detach bracket of oil line from timing case cover.

Scheme 187

Remove oil line from VANOS adjustment unit.

Scheme 188

Fit special tool 11 7 130 to VANOS adjustment unit. Connect compressed air (2 to 8 bar).

Scheme 189

Disconnect plug connection on solenoid valve.

Scheme 190

Connect special tool 12 6 050 in conjunction with special tool 12 6 411 (from special tool kit 12 6 410) to solenoid valves. Connect special tool 12 6 411 to correct terminals on car battery.

Alternately press toggle switch buttons 1 and 2 several times on special tool 12 6 050.

Scheme 191

Press and hold down toggle switch button 1 on special tool 12 6 050.

At same time, rotate inlet camshaft at hexagon drive against direction of rotation as far as it will go.

Scheme 192

Note. Spline teeth in VANOS gear are engaged; and inlet camshaft cannot be rotated further.

Alternately press toggle switch buttons 3 and 4 several times on special tool 12 6 050.

Scheme 193

Press and hold down toggle switch button 3 on special tool 12 6 050.

At same time, rotate exhaust camshaft at hexagon drive against direction of rotation as far as it will go.

Scheme 194

Note. Spline teeth in VANOS gear are engaged; and exhaust camshaft cannot be rotated further.

Disconnect compressed air from special tool 11 7 130.

Remove special tool 11 7 130.

Scheme 195

Scheme 196

Release screws (1).
Remove sliding rail (2).
Release screws (3).
Remove holder (4).

Remove special tool 11 2 300. Rotate crankshaft in direction of rotation a further revolution up to overlap TDC position.

Scheme 197

Note. TDC allocation above marking on vibration damper is sufficient.

Slacken six accessible bolts two turns.

Scheme 198

Crank engine at central bolt in direction of rotation until 1st cylinder is at TDC firing position. Secure vibration damper in position with special tool 11 2 300.

Scheme 199

Slacken remaining six bolts two turns.

Scheme 200

Release screws on VANOS adjustment unit.

Scheme 201

CAUTION

Do not damage VANOS adjustment unit.

Carefully detach VANOS adjustment unit.

Scheme 202

Inlet side

Note. The spline hub (1) accommodates a plate spring and a supporting ring.

Take care: the supporting ring can easily fall out when removed.

Remove slackened screws on inlet side.

Remove spline hub (1) with plate spring and supporting ring.

Scheme 203

Exhaust side

Note. The spline hub (1) accommodates a plate spring and a supporting ring.

Take care: the supporting ring can easily fall out when removed.

Remove slackened screws on exhaust side.

Remove spline hub (1) with plate spring and supporting ring.

Scheme 204

Remove chain tensioning piston. Refer to 11 31 090 REMOVING AND INSTALLING/REPLACING CHAIN TENSIONING PISTON (S54) .

Detach sprocket wheel (1 and 2) from centering sleeve.

Hold timing chain under tension.

Feed out sprocket wheel (1 and 2). Secure timing chain against slipping down.

Scheme 205

Remove special tool 11 2 300.

Scheme 206

CAUTION

No piston must be in the TDC position when the camshafts are removed.

Lift timing chain and hold under tension.

Crank engine at central bolt against direction of rotation to 30° before TDC position.

Scheme 207

Note. This work step is only necessary if the camshafts are to be replaced at a later stage.

Grip camshafts at hexagon head.

Release bolts on centering sleeves (1).

Remove centering sleeves (1) on exhaust and inlet sides with thrust washers (2)

Scheme 208

Note. This work step is only necessary if the camshafts are to be replaced at a later stage.

Withdraw toothed sleeves (3) from exhaust and inlet camshafts.

Scheme 209

Remove profile seal (1)

Scheme 210

Note. Inlet and exhaust camshafts have a joint thrust bearing flange at 1st bearing seat. Thrust bearing flange is secured with adapter sleeves.

Release nuts and remove thrust bearing flange (1).

Scheme 211

Removing inlet camshaft

CAUTION

Note direction and angle of rotation.

Rotate inlet camshaft at hexagon inwards until cam tips on 1st cylinder are horizontal.

Scheme 212

Inlet side

CAUTION

Incorrect removal/installation without a special tool exposes the camshaft to the risk of preliminary damage or breakage.

Fit special tool 11 4 380 on inlet camshaft and screw into spark plug threads of cylinders 2 and 5.

Pretension inlet camshaft by rotating eccentric shaft. Release all nuts of bearing caps on inlet camshaft.

Scheme 213

Inlet side

Note. Bearing caps are secured with adapter sleeves. Bearing caps are marked E2 to E7.

Feed out bearing caps E2 to E7 and set down in order.

Scheme 214

Inlet side

CAUTION

Inlet camshaft must not tilt when tension is relieved on special tool 11 4 380.

Relieve tension on special tool 11 4 380 and remove. Lift out inlet camshaft.

Scheme 215

Removing exhaust camshaft

CAUTION

Note direction and angle of rotation.

Rotate exhaust camshaft at hexagon inwards until cam tips on 1st cylinder are horizontal.

Scheme 216

Exhaust side

CAUTION

Incorrect removal/installation without a special tool exposes the camshaft to the risk of preliminary damage or breakage.

Fit special tool 11 4 380 on exhaust camshaft and screw into spark plug threads of cylinders 2 and 5.

Pretension exhaust camshaft by rotating eccentric shaft. Release all nuts of bearing caps on exhaust camshaft.

Scheme 217

Exhaust side

Note. Bearing caps are secured with adapter sleeves. Bearing caps are marked A2 to A7.

Feed out bearing caps A2 to A7 and set down in order.

Scheme 218

Exhaust side

CAUTION

Exhaust camshaft must not tilt when tension is relieved on special tool 11 4 380.

Relieve tension on special tool 11 4 380 and remove. Lift out exhaust camshaft.

Scheme 219

If necessary, removing signal disk of exhaust and inlet camshafts

CAUTION

Do not damage camshafts. Use protective vise jaws.

Grip camshaft at hexagon in a vise and release banjo bolt (1).

Scheme 220

Installation

Installation of camshafts and the VANOS adjustment unit is described separately from removal. The assembly sequence for removal and installation is different.

CAUTION

Danger of mixing up

The inlet camshaft has an identifying groove behind the locating bore.

Scheme 221

(A) Exhaust camshaft without groove.
(E) Inlet camshaft with groove.

Note. Signal rings of inlet and exhaust camshafts are different.

(A) Signal disk of exhaust camshaft with seven blades.

(E) Signal disk of inlet camshaft with six blades. Fit signal disks, align locating lug to groove.

Scheme 222

Install banjo bolt (1) and tighten down.

Tightening torque, refer to 11 31 13AZ in ENGINE - TIGHTENING TORQUES .

Scheme 223

Note. Clean dirty parts. Oil following parts before installation: Contact faces of camshafts in cylinder head. Rocker arm. Cams and contact faces of camshafts. Bearing cover.

Installing inlet camshaft

Install inlet camshaft in such a way that cams on cylinder 1 point horizontally inwards.

Scheme 224

Inlet side

CAUTION

Incorrect removal/installation without a special tool exposes the camshaft to the risk of preliminary damage or breakage.

Fit special tool 11 4 380 on inlet camshaft and screw into spark plug threads of cylinders 2 and 5.

Scheme 225

Inlet side

Pretension inlet camshaft by rotating eccentric shaft.

Scheme 226

Inlet side

CAUTION

Risk of mixing up parts. Fit inlet side bearing caps so that lug (2) points outwards to inlet side.

Note. Bearing caps are secured with adapter sleeves (1).

Check dowel sleeves (1) for damage and correct installation position.

Scheme 227

Inlet side

Note. Bearing caps are marked E2 to E7.

Install bearing caps E2 to E7.

Scheme 228

Inlet side

Align bearing caps by hand until they are secured by means of adapter sleeves.

Insert all nuts of bearing caps on inlet camshaft.

Manually tighten bearing cap nuts and then tighten down from inside to outside in 1/2 turn increments.

Tightening torque, refer to 11 31 1AZ in ENGINE - TIGHTENING TORQUES .

Remove special tool 11 4 380.

Scheme 229

Inlet side

CAUTION

Note direction and angle of rotation.

Rotate inlet camshaft at hexagon from horizontal position upwards until locating bore (1) in camshaft is vertical.

Scheme 230

CAUTION

Pay attention to installation direction of special tool 11 9 130. (A) Exhaust side. (E) Inlet side.

Scheme 231

Inlet side

Attach special tool 11 9 130 to cylinder head.

Align inlet camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Special tool 11 9 130 must rest flat on cylinder head. Remove special tool 11 9 130 and special tool 11 7 342.

Scheme 232

Installing exhaust camshaft

Clean dirty parts.

Oil following parts before installation

Contact faces of camshafts in cylinder head.
Rocker arm.
Cams and contact faces of camshafts.
Bearing cover.

Install exhaust camshaft in such a way that cams on cylinder 1 point horizontally inwards.

Scheme 233

Exhaust side

CAUTION

Incorrect removal/installation without a special tool exposes the camshaft to the risk of preliminary damage or breakage.

Fit special tool 11 4 380 on exhaust camshaft and screw into spark plug threads of cylinders 2 and 5.

Scheme 234

Exhaust side

Pretension exhaust camshaft by rotating eccentric shaft.

Scheme 235

Exhaust side

CAUTION

Risk of mixing up parts. Fit exhaust side bearing caps so that lug (2) points outwards to exhaust side.

Note. Bearing caps are secured with adapter sleeves (1).

Check dowel sleeves (1) for damage and correct installation position.

Scheme 236

Exhaust side

Note. Bearing caps are marked A2 to A7.

Install bearing caps A2 to A7.

Scheme 237

Exhaust side

Align bearing caps by hand until they are secured by means of adapter sleeves.

Insert all nuts of bearing caps on exhaust camshaft.

Manually tighten bearing cap nuts and then tighten down from inside to outside in 1/2 turn increments.

Tightening torque, refer to 11 31 1AZ in ENGINE - TIGHTENING TORQUES .

Remove special tool 11 4 380.

Scheme 238

Exhaust side

CAUTION

Note direction and angle of rotation.

Rotate exhaust camshaft at hexagon from horizontal position upwards until locating bore (1) in camshaft is vertical.

Scheme 239

CAUTION

Pay attention to installation direction of special tool 11 9 130. (A) Exhaust side. (E) Inlet side.

Scheme 240

Exhaust side

Attach special tool 11 9 130 to cylinder head.

Align exhaust camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Special tool 11 9 130 must rest flat on cylinder head.

Remove special tool 11 9 130 and special tool 11 7 342.

Scheme 241

Note. Inlet and exhaust camshafts have a joint thrust bearing flange (1) at 1st bearing seat.

Check adapter sleeves (2) for damage and correct installation position.

Observing installation direction

Fit thrust bearing flange (1) as shown in illustration.

Scheme 242

Align thrust bearing flange (1) by hand until it is secured to cylinder head by means of adapter sleeves.

Install nuts of thrust bearing flange (1).

Manually tighten nuts and then tighten down from in 1/2 turn increments.

Scheme 243

Coat toothing of toothed sleeves (3) with engine oil as antiseize agent.

Install toothed sleeves (3) of exhaust and inlet camshafts. Align bores in toothed sleeves (3) to tapped holes in camshafts.

Scheme 244

CAUTION

Note installation direction of thrust washers (2). Large chamfer points to camshaft.

Scheme 245

Note installation direction of thrust washers (2).

Fit thrust washers (2) on centering sleeves (1) in such a way that large chamfer points towards rear to camshaft.

Scheme 246

Fit centering sleeve (1) on exhaust and inlet sides with thrust washer (2).

Grip camshafts at hexagon head.

Tighten down bolts on centering sleeves (1).

Scheme 247

Inlet side

CAUTION

Pay attention to installation direction of special tool 11 9 130.

Attach special tool 11 9 130 to cylinder head. Align inlet camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Special tool 11 9 130 must rest flat on cylinder head. Remove special tool 11 7 342.

Scheme 248

Exhaust side

Align exhaust camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Special tool 11 9 130 must rest flat on cylinder head.

Remove special tool 11 9 130 and special tool 11 7 342.

Scheme 249

Lift timing chain and hold under tension.

Rotate crankshaft from 30° before TDC position in direction of rotation as far as firing TDC position. Secure vibration damper in position with special tool 11 2 300.

Scheme 250

Hold timing chain under tension.

Position tapped holes of thrust washer horizontally as shown in illustration.

Install sprocket wheel (2) on inlet side on centering sleeves in such a way that elongated holes are centrally located.

Note. The position of the elongated holes is only important in terms of accessibility to the screws and does not affect operation in any way.

Scheme 251

Hold timing chain under tension and feed on sprocket wheel (1).

Install sprocket wheel (1) on exhaust side on centering sleeves in such a way that elongated holes of sprocket wheels (1 and 2) are centrally located.

Press tensioning rail against timing chain and check position of elongated holes.

Note. The position of the elongated holes is only important in terms of accessibility to the screws and does not affect operation in any way.

Scheme 252

Install chain tensioning piston. Refer to 11 31 090 REMOVING AND INSTALLING/REPLACING CHAIN TENSIONING PISTON (S54) .

Note. Coat all sliding surfaces on VANOS gear with engine oil as antiseize agent.

Exhaust side

Note. The small support diameter of the plate spring (2) points in the direction of the supporting ring (3). Supporting ring is supported with retaining lugs in spline hub (1).

Insert plate spring (2) and supporting ring (3) in spline hub (1).

Scheme 253

Exhaust side

Take care: the supporting ring can easily fall out.

Remove spline hub with plate spring and supporting ring.

Bore hole (1) must point upwards as shown in illustration.

Scheme 254

Exhaust side

Insert all screws of spline hub (1) and tighten by hand until free of play.

Then slacken screws again until spline hub (1) can be moved with fingers.

Scheme 255

Inlet side

Note. The small support diameter of the plate spring (2) points in the direction of the supporting ring (3). Supporting ring is supported with retaining lugs in spline hub (1).

Insert plate spring (2) and supporting ring (3) in spline hub (1).

Scheme 256

Inlet side

Take care: the supporting ring can easily fall out.

Remove spline hub with plate spring and supporting ring.

Bore hole (1) must point upwards as shown in illustration.

Scheme 257

Inlet side

Insert all screws of spline hub (1) and tighten by hand until free of play.

Then slacken screws again until spline hub (1) can be move with fingers.

Scheme 258

Detach control valve (1) from VANOS adjustment unit.

Scheme 259

Note. A filter is integrated in the control valve.

The control valve must be replaced after any engine damage which suggests that the filter is fouled with filings/shavings.

Replace sealing rings (1) and coat with oil as antiseize agent. Preassemble control valve in cylinder head.

Scheme 260

Oil is sprayed when splined shafts are pressed back. Cover bore (1) with a cloth.

Connect special tool 12 6 050 in conjunction with special tool 12 6 411 (from special tool kit 12 6 410) to solenoid valves of VANOS adjustment unit. Connect special tool 12 6 411 to correct terminals on car battery.

Press buttons 1 and 3 on special tool 12 6 050 simultaneously. Solenoid valves are actuated.

Press splined shafts by hand up to stop into initial position.

Scheme 261

Check dowel sleeves (1) for damage and correct installation position.

Scheme 262

Replace gasket (1).

CAUTION

Note direction of installation of gasket. Install gasket (1) in such a way that beading points to VANOS adjustment unit. Secure gasket (1) with sealing compound on adapter sleeves.

Scheme 263

Secure special tool 11 9 170 as shown in illustration by means of stud bolt.

Note. The special tool 11 9 170 serves to maintain a prespecified distance during the below-mentioned installation of the VANOS adjustment unit.

Scheme 264

Turn spline hubs (1) of inlet and exhaust camshafts to right limit position.

Scheme 265

Note. Special tool 11 9 170 remains as a spacer element between cylinder head and VANOS adjustment unit.

Attach VANOS adjustment unit.

Scheme 266

CAUTION

Make sure both VANOS splined shafts remain in initial position during installation.

Rotate splined shafts of inlet and exhaust sides until spur toothing is engaged.

Push VANOS adjustment unit with splined shaft into VANOS gear until helical cut splines (2) are positioned shortly before meshing with spline hub (1).

Scheme 267

Exhaust side

If the helical cut splines cannot be pushed into the spline hub (1)

Place special tool 11 7 160 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".

CAUTION

The "first" matching tooth must engage.

Scheme 268

Inlet side

Place special tool 11 7 160 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".

CAUTION

The "first" matching tooth must engage.

Scheme 269

Exhaust side

Align radial piston pump to driver on spline hub.

Note. Picture shows a schematic representation.

Scheme 270

Push on VANOS adjustment unit until it contacts special tool 11 9 170.

CAUTION

If this position is not reached, realign position of radial piston pump to driver.

Scheme 271

CAUTION

Do not tighten down screws.

Note. Screw on left and right serves to secure the VANOS adjustment unit.

Insert a screw on left and right and tighten by hand until free of play.

Scheme 272

Note. The procedure described below helps to provide compensation for play. Only with this compensation for play is the timing diagram correctly set.

Note. To tighten down screws on VANOS gear: Use special tool 11 7 200.

Tighten down the two opposing screws on the inlet and exhaust sides of the VANOS gear to 10 N.m.

Then slacken all four screws by a 1/4 turn.

Scheme 273

Remove special tool 11 9 170 on left and right sides.

Scheme 274

CAUTION

Make sure that radial piston pump is aligned to driver on spline hub. When the left and right screws are tightened down alternately, the exhaust and inlet camshafts must not rotate. If the camshafts do rotate, this means that the screws on the VANOS gear were not previously released correctly.

Alternately tighten down bolts in 1/2 turn increments carefully and evenly until VANOS adjustment unit rests against timing P case cover.

Scheme 275

Insert remaining screws and tighten down.

Scheme 276

Note. Use special tool 11 7 200 to tighten down bolts on VANOS gear.

Scheme 277

Tighten down six accessible screws (three on exhaust side and three on inlet side) on VANOS gear to 10 N.m.

Scheme 278

Remove special tool 11 2 300. Rotate crankshaft in direction of rotation a further revolution up to overlap TDC position.

Note. TDC allocation above marking on vibration damper is sufficient.

Scheme 279

Note. Use special tool 11 7 200 to tighten down bolts on VANOS gear.

Scheme 280

Tighten down remaining six screws (three on exhaust side and there on inlet side) on VANOS gear 10 N.m.

Scheme 281

Then crank engine again in direction of rotation until 1st cylinder is at TDC firing position.

Secure vibration damper in position with special tool 11 2 300.

Scheme 282

Check camshaft setting

Attach special tool 11 9 140 and join in inlet camshaft.

Note. The inlet camshaft is correctly adjusted when special tool 11 9 140 rests flat on the cylinder head or protrudes by max. 0.5 mm to the exhaust side.

If the special tool 11 9 140 protrudes to the inlet side, the timing must be readjusted.

Scheme 283

Join special tool 11 9 140 in exhaust camshaft.

Note. The exhaust camshaft is correctly adjusted when special tool 11 9 140 rests flat on the cylinder head or protrudes by max. 0.5 mm to the exhaust side.

If the special tool 11 9 140 protrudes to the inlet side, the timing must be readjusted.

If necessary, adjust camshaft timing. Refer to 11 31 505 ADJUSTING CAMSHAFT TIMING (S54) .

Scheme 284

Note. Check installed direction.

Install holder (4)

Scheme 285

Scheme 286

Insert screws (3) and secure holder (4) (do not tighten down screws (3) yet)
Install sliding rail (2).
Insert screws (1).
Tighten down screws (1) and screws (3).

Replace sealing rings of banjo bolt.

Insert banjo bolt but do not tighten down yet.

Scheme 287

Install bracket of oil line. Install screw and tighten down.

Scheme 288

Tighten down banjo bolt of oil line.

Tightening torque, refer to 11 36 9AZ in ENGINE - TIGHTENING TORQUES .

Scheme 289

Remove special tool 11 2 300.

Adjust valves. Refer to 11 34 004 ADJUSTING VALVE CLEARANCE (S54) .

Assemble engine.

Scheme 290

CAUTION

11 31 090 Removing And Installing/Replacing Chain Tensioning Piston (S54)

E46 Only

Remove expansion rivet. Remove air duct (1).

Scheme 291

Scheme 291: 11 31 090 Removing And Installing/Replacing Chain Tensioning Piston (S54)

CAUTION

Strong spring force. Have a cleaning cloth ready. A small quantity of oil will emerge after the screw connection has been released. Make sure no oil runs onto belt drive. Remove any remnants of oil immediately with cleaning cloth.

Unfasten screw connection.

Remove chain tensioning piston. Refer to 11 31 090 REMOVING AND INSTALLING/REPLACING CHAIN TENSIONING PISTON (S54) .

Scheme 292

Installation

If a chain tensioner is reused, its oil chamber must be drained.

Place chain tensioner on a level surface and compress slowly and carefully.

Repeat this procedure twice.

Scheme 293

Installation

Install hydraulic chain tensioner (1) in cylinder for chain tensioning piston (2).

Replace sealing ring (3).

Install and tighten down cylinder for chain tensioning piston (2).

Tightening torque, refer to 11 31 8AZ in ENGINE - TIGHTENING TORQUES .

Scheme 294

11 31 505 Adjusting camshaft timing (S54)

Special Tools Required

11 2 300
11 5 100
11 7 160
11 7 200
11 7 342
11 9 130
11 9 140
11 9 170
12 6 050
12 6 410
12 6 411 (Refer to «11 31 005 CHECKING CAMSHAFT TIMING (S54)»(/bmw/m3/e46-1999-2006/remont/mechanical/#engine-repair-s54__11-31-005-checking-camshaft-timing) .)

When the engine is switched off, VANOS moves the camshafts to a position which is advantageous to engine starting.

CAUTION

The timing must "not" be adjusted in this position. The camshafts must be rotated back to their initial position beforehand and the timing checked.

Check camshaft timing. Refer to 11 31 005 CHECKING CAMSHAFT TIMING (S54) .

If the timing check reveals an impermissible deviation, the VANOS adjustment unit must be removed and the camshaft timing readjusted.

Scheme 295

Release screws (1).
Remove sliding rail (2).
Release screws (3).
Remove holder (4).

Attach special tool 11 5 100 to four screws of crankshaft hub.

Scheme 296

Remove special tool 11 2 300. Rotate crankshaft in direction of rotation a further revolution up to overlap TDC position.

Note. TDC allocation above marking on vibration damper is sufficient.

Scheme 297

Slacken six accessible bolts two turns.

Scheme 298

Crank engine at central bolt in direction of rotation until 1st cylinder is at TDC firing position. Secure vibration damper in position with special tool 11 2 300.

Scheme 299

Slacken remaining six bolts two turns.

Scheme 300

Release screws on VANOS adjustment unit.

Scheme 301

CAUTION

Do not damage VANOS adjustment unit.

Carefully detach VANOS adjustment unit.

Scheme 302

CAUTION

Pay attention to installation direction of special tool 11 9 130. (A) Exhaust side. (E) Inlet side.

Scheme 303

Inlet side

CAUTION

Pay attention to installation direction of special tool 11 9 130.

Attach special tool 11 9 130 to cylinder head. Align inlet camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Special tool 11 9 130 must rest flat on cylinder head. Remove special tool 11 7 342.

Scheme 304

Exhaust side

Align exhaust camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Special tool 11 9 130 must rest flat on cylinder head. Remove special tool 11 9 130 and special tool 11 7 342.

Scheme 305

Tighten all screws of spline hub (1) on inlet and outlet sides by hand until free from play.

Then slacken screws again until spline hubs (1) can be moved) with fingers.

Scheme 306

Detach control valve (1) from VANOS adjustment unit.

Scheme 307

Note. A filter is integrated in the control valve.

In the event of engine damage which suggests that the filter is contaminated with swarf/chips, it is essential to replace the control valve.

Replace sealing rings (1) and coat with oil as antiseize agent. Preassemble control valve in cylinder head.

Scheme 308

Oil is sprayed when splined shafts are pressed back. Cover bore (1) with a cloth.

Press buttons 1 and 3 on special tool 12 6 050 simultaneously. Solenoid valves are actuated.

Press splined shafts by hand up to stop into initial position.

Scheme 309

Check adapter sleeves (1) for damage and correct installation position.

Scheme 310

Replace gasket (1).

CAUTION

Note direction of installation of gasket. Install gasket (1) in such a way that beading points to VANOS adjustment unit. Secure gasket (1) with sealing compound on adapter H sleeves.

Scheme 311

Secure special tool 11 9 170 - as shown in illustration - by means of stud bolt.

Note. The special tool 11 9 170 serves to maintain a prespecified distance during the below-mentioned installation of the VANOS adjustment unit.

Scheme 312

Turn spline hubs (1) of inlet and exhaust camshafts to right limit position

Scheme 313

Note. Special tool 11 9 170 remains as a spacer element between cylinder head and VANOS adjustment unit.

Attach VANOS adjustment unit.

Scheme 314

CAUTION

Make sure both VANOS splined shafts remain in initial position during installation.

Rotate splined shafts of inlet and exhaust sides until spur toothing is engaged.

Push VANOS adjustment unit with splined shaft into VANOS gear until helical cut splines (2) are positioned shortly before meshing with spline hub (1).

Scheme 315

Exhaust side

If the helical cut splines cannot be pushed into the spline hub (1)

Place special tool 11 7 160 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".

CAUTION

The "first" matching tooth must engage.

Scheme 316

Inlet side

Place special tool 11 7 160 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".

CAUTION

The "first" matching tooth must engage.

Scheme 317

Exhaust side

Align radial piston pump to driver on spline hub.

Note. Picture shows a schematic representation.

Scheme 318

Push on VANOS adjustment unit until it contacts special tool 11 9 170.

CAUTION

If this position is not reached, realign position of radial piston pump to driver.

Scheme 319

CAUTION

Do not tighten down screws.

Note. Screw on left and right serves to secure the VANOS adjustment unit.

Insert a screw on left and right and tighten by hand until free of play.

Scheme 320

Note. The procedure described below helps to provide compensation for play. Only with this compensation for play is the timing diagram correctly set.

Note. To tighten down screws on VANOS gear: Use special tool 11 7 200.

Tighten down the two opposing screws on the inlet and exhaust sides of the VANOS gear to 10 N.m.

Then slacken all four screws by a 1/4 turn.

Scheme 321

Remove special tool 11 9 170 on left and right sides.

Scheme 322

CAUTION

Alternately tighten down bolts in 1/2 turn increments carefully and evenly until VANOS adjustment unit rests against timing case cover.

Scheme 323

Insert remaining screws and tighten down.

Scheme 324

Note. Use special tool 11 7 200 to tighten down bolts on VANOS gear.

Scheme 325

Tighten down six accessible screws (three on exhaust side and three on inlet side) on VANOS gear to 10 N.m.

Scheme 326

Remove special tool 11 2 300. Rotate crankshaft in direction of rotation a further revolution up to overlap TDC position.

Note. TDC allocation above marking on vibration damper is sufficient.

Scheme 327

Note. Use special tool 11 7 200 to tighten down bolts on VANOS gear.

Scheme 328

Tighten down remaining six screws (three on exhaust side and three on inlet side) on VANOS gear to 10 N.m.

Scheme 329

Then crank engine again in direction of rotation until 1st cylinder is at TDC firing position.

Secure vibration damper in position with special tool 11 2 300.

Scheme 330

Check camshaft setting

Attach special tool 11 9 140 and join in inlet camshaft.

Note. The inlet camshaft is correctly adjusted when special tool 11 9 140 rests flat on the cylinder head or protrudes by max. 0.5 mm to the exhaust side.

If the special tool 11 9 140 protrudes to the inlet side, the timing must be readjusted.

Scheme 331

Join special tool 11 9 140 in exhaust camshaft.

Note. The exhaust camshaft is correctly adjusted when special tool 11 9 140 rests flat on the cylinder head or protrudes by max. 0.5 mm to the exhaust side.

If the special tool 11 9 140 protrudes to the inlet side, the timing must be readjusted.

Scheme 332

Note. Check installed direction.

Install holder (4)

Scheme 333

Scheme 334

Insert screws (3) and secure holder (4) (do not tighten down screws (3) yet)
Install sliding rail (2).
Insert screws (1).
Tighten down screws (1) and screws (3).

Replace sealing rings of banjo bolt.

Install banjo bolt do not tighten down yet

Scheme 335

Install bracket of oil line. Install screw and tighten down.

Scheme 336

Tighten down banjo bolt of oil line.

Tightening torque, refer to 11 36 9AZ in ENGINE - TIGHTENING TORQUES .

Scheme 337

Remove special tool 11 2 300.

Assemble engine

Scheme 338

CAUTION

11 33 545 Removing And Installing/Replacing Rocker Arm Shaft (S54)

(Cylinder head removed.)
(If necessary inlet or exhaust side.)

CAUTION

It is very easy for the adjustment plates to fall down.

Raise rocker arm.

Note. The special tool 11 4 400 is magnetic.

Remove all adjustment plates with special tool 11 4 400 and set to one side order

Scheme 339

Detach spring clip (1).

Scheme 340

Remove camshaft sensor.

Installation

Replace O-ring and screw.

Release journal screw (1).

Scheme 341

Note. If the rocker arm shaft cannot be removed by hand towards the front

Open screw plug (1).

Installation

Replace sealing ring on plug (1).

Tightening torque, refer to 11 33 2AZ in ENGINE - TIGHTENING TORQUES .

Scheme 342

Slide out rocker arm shaft towards front.

Note. Place fingers to one side in orderly fashion. Worn rocker arms should only be reused at the same cam on the camshaft.

CAUTION

If the inlet and exhaust rocker arm shafts are mixed up: engine damage!

Scheme 343

(1) Inlet rocker arm shaft.
(2) Exhaust rocker arm shaft.
(3) Groove for identifying inlet rocker arm shaft.
(4) Opening for journal screw. The groove for identifying the inlet rocker arm shaft is located between the 5th and 6th cylinders.

Note. Difference between inlet and exhaust rocker arm shafts, front. (1) Inlet rocker arm shaft, front, open. (2) Exhaust rocker arm shaft, front, closed.

Installation

Install rocker arm shaft and feed on rocker arm in so doing.

Align opening for journal screw precisely to cylinder head and insert journal screw (1).

Tighten down journal screw (1).

Tightening torque, refer to 11 33 3AZ in ENGINE - TIGHTENING TORQUES .

Scheme 344

Align rocker arm to valve.

Note. Spring clip (1) must snap into place over rocker arm shaft.

Install spring clip (1).

Scheme 345

CAUTION

It is very easy for the adjustment plates to fall down.

Install adjustment plates for valve clearance only after cylinder head has been installed.

11 34 004 Adjusting valve clearance (S54)

Special Tools Required

11 3 160
11 4 400
11 5 100 Remove cylinder head cover. Refer to «11 12 000 Removing And Installing, Sealing Cylinder Head Cover (S54)»(/bmw/m3/e46-1999-2006/remont/mechanical/#engine-repair-s54__11-12-000-removing-and-installing) . Remove fan clutch with fan impeller and fan cowl. Refer to «11 52 020 REMOVING AND INSTALLING/REPLACING FAN CLUTCH (S52 / S54 / M52 / M52TU / M54 / M56)»(/bmw/m3/e46-1999-2006/remont/mechanical/#engine-repair-s54__11-52-020-removing-and-installingreplacing) and «17 11 031 REPLACING FAN COWL (S54)»(/bmw/m3/e46-1999-2006/remont/cooling-system-mechanical/#cooling-system-repair__17-11-031-replacing-fan-cowl) . Remove spark plugs. Refer to «12 12 011 REPLACING ALL SPARK PLUGS (S54)»(/bmw/m3/e46-1999-2006/remont/gauges-instrument-panels/#engine-electrical-system-repair__12-12-011-replacing-all-spark) .

Note. Fit special tool 11 5 100 on four screws on vibration damper and crank engine.

Scheme 346

With cams pointing upwards, measure valve clearance with special tool 11 3 160.

Note down measured values.

Compare measured valve clearance with prespecified ventil clearance. Refer to ENGINE - TECHNICAL DATA .

Scheme 347

If the measured valve clearance is outside the stipulated valve clearance tolerance

CAUTION

It is very easy for the adjustment plates to fall down.

Place a clean cloth underneath the valve to be adjusted. Seal oil return and vent holes.

Seal opening to timing case cover at first cylinder. Seal spark plug bores.

CAUTION

Do not damage sealing surface for cylinder head cover.

Carefully detach retaining clip (1) from rocker arm shaft.

Scheme 348

CAUTION

It is very easy for the adjustment plates to fall down. Carefully slide rocker arm to one side.

Scheme 349

Note. Special tool 11 4 400 is magnetic.

Remove adjustment plates with special tool 11 4 400.

Scheme 350

Measure removed adjustment plates.

Scheme 351

CAUTION

It is very easy for the adjustment plates to fall down.

Insert required adjustment plates with special tool 11 4 400.

Scheme 352

CAUTION

Incorrect installation possible!

When the rocker arm is pushed back, there is the risk that the adjustment plate will also be pushed out.

Carefully push rocker arm back and check correct position of adjustment plates.

Note. If necessary, check correct position of adjustment plates with a mirror.

Scheme 353

CAUTION

Do not damage sealing surface for cylinder head cover.

Install retaining clip (1).

CAUTION

Retaining clip (1) must snap into place on left and right over rocker arm shaft (2).

Check valve clearance. Refer to ENGINE - TECHNICAL DATA .

Scheme 354

11 34 552 Removing And Installing Or Replacing All Valves - Cylinder Head Removed (S54)

Preliminary tasks are described in 11 12 503 DISASSEMBLING AND ASSEMBLING CYLINDER HEAD - CYLINDER HEAD REMOVED (S54) .

Replace valve stem seals. Refer to 11 34 560 REPLACING ALL VALVE STEM SEALS - CYLINDER HEAD REMOVED (S50 / S54) .

Remove valves from cylinder head.

If necessary, check valve guide for wear. Refer to 11 12 595 CHECKING A VALVE GUIDE FOR WEAR - VALVE REMOVED (S50/S54) .

If necessary, remachine valve seat. Refer to 11 12 527 REMACHINING A VALVE SEAT - CYLINDER HEAD DISASSEMBLED (S50/S54) .

CAUTION

Incorrect installation possible. Incorrect installation will result in valve spring breakage.

The valve spring coils are narrower at the lower ends.

The color coding (3) is normally located at the lower end of the valve springs.

Only the position of the narrower coil is the decisive factor in correct installation of the valve springs (1 and 2).

Install valve springs (1 and 2) in such a way that lower coil points to spring plate at bottom.

Scheme 355

Arrangement

Scheme 356

Valve.
Lower plate spring.
Valve-stem seal.
Outer spring.
Inner spring.
Top spring plate.
Valve tapers.

11 34 560 Replacing All Valve Stem Seals - Cylinder Head Removed (S50/S54)

Note. For Special Tool identification, see SPECIAL TOOLS - M3 .

Special Tools Required

11 1 200
11 1 380
11 1 480
11 1 960 Preliminary tasks are described in «11 12 503 DISASSEMBLING AND ASSEMBLING CYLINDER HEAD - CYLINDER HEAD REMOVED (S54)»(/bmw/m3/e46-1999-2006/remont/mechanical/#engine-repair-s54__11-12-503-disassembling-and-assembling) .

Remove valve stem seal with special tool 11 1 480.

Scheme 357

S50 B32 And S54

Valve stem diameter 6 mm

Installation

Lubricate valve stem with oil and insert valve.

Fit special tool 11 1 960.

Coat new valve stem seal (1) with oil and install.

Scheme 358

Note. Special tool 11 1 200 is used for valve stem diameters 6 mm and 7 mm.

Installation

Press valve stem seal firmly home by hand with special tool 11 1 200.

Scheme 359

11 34 715 Replacing All Valve Seals - Cylinder Head Removed (S54)

Preliminary tasks are described in Disassembling and assembling cylinder head. Refer to 11 12 503 DISASSEMBLING AND ASSEMBLING CYLINDER HEAD - CYLINDER HEAD REMOVED (S54) .

Align special tool 11 0 345 in direction to valve shaft and select corresponding groove in special tool 11 0 342.

Press down valve spring on spring plate at top with special tool 11 0 342 and hook in special tool 11 0 343 to special tool 11 1 065.

Scheme 360

Scheme 360: 11 34 715 Replacing All Valve Seals - Cylinder Head Removed (S54)

Remove valve cones.

Remove valve spring and spring plate.

Scheme 361

CAUTION

Incorrect installation possible. Incorrect installation will result in valve spring breakage.

The valve spring coils are narrower at the lower ends.

The color coding (3) is normally located at the lower end of the valve springs.

Only the position of the narrower coil is the decisive factor in correct installation of the valve springs (1 and 2).

Install valve springs (1 and 2) in such a way that lower coil points to spring plate at bottom.

Scheme 362

Note. In event of damage to an inner or outer spring: replace inner and outer valve springs.

Arrangement

Scheme 363

Valve.
Lower plate spring.
Valve-stem seal.
Outer spring.
Inner spring.
Top spring plate.
Valve tapers.

11 36 010 Removing And Installing, Sealing/Replacing VANOS Adjustment Unit (S54)

Special Tools Required

11 5 100
11 7 130
12 6 050
12 6 410
12 6 411 Read fault memory and make a documentary record.

Remove cylinder head. Refer to 11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD (S54) .

Remove all spark plugs. See 12 12 011 REPLACING ALL SPARK PLUGS (S54)

Remove fan clutch with fan impeller and fan cowl. Refer to 11 52 020 REMOVING AND INSTALLING/REPLACING FAN CLUTCH (S52 / S54 / M52 / M52TU / M54 / M56) and 17 11 031 REPLACING FAN COWL (S54) .

Removal

The removal of the VANOS adjustment unit is described separately from the installation. The assembly sequence for removal and installation is different.

Fit special tool 11 5 100 to four screws on crankshaft hub.

Scheme 364

Scheme 364: Removal

Rotate crankshaft in direction of rotation as far as firing TDC position of 1st cylinder.

Scheme 365

Note. TDC allocation above marking on vibration damper is sufficient.

Scheme 366

CAUTION

Detach bracket of oil line from timing case cover.

Scheme 367

Remove oil line from VANOS adjustment unit.

Scheme 368

Fit special tool 11 7 130 to VANOS adjustment unit.

Connect compressed air (2 to 8 bar)

Scheme 369

Disconnect plug connection on solenoid valve.

Scheme 370

Connect special tool 12 6 050 in conjunction with special 1 tool 12 6 411 (from special tool kit 12 6 410) to solenoid valves.

Connect special tool 12 6 411 to correct terminals on car battery.

Alternately press toggle switch buttons 1 and 2 several times on special tool 12 6 050.

Scheme 371

Press and hold down toggle switch button 1 on special tool 12 6 050.

At same time, rotate inlet camshaft at hexagon drive against direction of rotation as far as it will go.

Note. Spline teeth in VANOS gear are engaged; and inlet camshaft cannot be rotated further.

Scheme 372

Alternately press toggle switch buttons 3 and 4 several times on special tool 12 6 050.

Scheme 373

Press and hold down toggle switch button 3 on special tool 12 6 050.

At same time, rotate exhaust camshaft at hexagon drive against direction of rotation as far as it will go.

Note. Spline teeth in VANOS gear are engaged; and exhaust camshaft cannot be rotated further.

Scheme 374

Disconnect compressed air from special tool 11 7 130.

Scheme 375

Scheme 376

Release screws (1).
Remove sliding rail (2).
Release screws (3).
Remove holder (4).

Release screws on VANOS adjustment unit.

Scheme 377

CAUTION

Make sure that compressed air is "not" connected.

Press buttons 2 and 4 on special tool 12 6 050. The solenoid valves are activated and the oil chamber of the hydraulic piston is ventilated.

CAUTION

Do not damage VANOS adjustment unit.

Carefully detach VANOS adjustment unit from adapter sleeves in cylinder head.

Scheme 378

Detach VANOS adjustment unit until hydraulic pistons on exhaust and inlet sides are extended.

CAUTION

CCW thread! Brace against twin surface (1) and release hex head (2).

Release screw connection of toothed shaft on inlet and exhaust sides, supporting VANOS adjustment unit with your hand in the process.

Scheme 379

Remove VANOS adjustment unit.

Note. The toothed shafts (1) remain in the VANOS gear on the engine.

Scheme 380

CAUTION

The engine must not be cranked while the VANOS adjustment unit is removed. The toothed shafts might displace and slip out of the spline teeth; the camshafts would no longer be non-positively connected and the valves could touch the piston.

Detach control valve (1) from VANOS adjustment unit.

Scheme 381

The installation of the VANOS adjustment unit is described separately from the removal. The assembly sequence for removal and installation is different.

Note. Procedure for replacement or new parts: When delivered, the hydraulic pistons (1) of the VANOS adjustment unit are "retracted" and the hexagons are not accessible. Fit special tool 11 7 130 to VANOS adjustment unit.

CAUTION

Oil is sprayed when compressed air is connected. Cover bore (2) with a cloth.

Connect compressed air (2 to 8 bar).

Scheme 382

Connect special tool 12 6 050 in conjunction with special tool 12 6 411 to solenoid valves of VANOS adjustment unit.

Connect special tool 12 6 411 to correct terminals on car battery.

Press buttons 2 and 4 on special tool 12 6 050. The solenoid valves are activated and the oil chamber of the hydraulic piston is ventilated. The hydraulic pistons (1) extend.

Disconnect compressed air from special tool 11 7 130. Remove special tool 11 7 130 from VANOS adjustment unit.

Scheme 383

Note. A filter is integrated in the control valve.

In the event of engine damage which suggests that the filter is contaminated with swarf/chips, it is essential to replace the control valve.

Replace sealing rings (1) and coat with oil as antiseize agent.

Preassemble controlled valve in cylinder head.

Scheme 384

Check dowel sleeves (1) for damage and correct installation position.

Scheme 385

Replace gasket (1).

CAUTION

Note direction of installation of gasket. Install gasket (1) in such a way that beading points to VANOS adjustment unit. Secure gasket (1) with sealing compound on.

Scheme 386

Place VANOS adjustment unit on toothed shafts (1).

Scheme 387

CAUTION

CCW thread! When tightening down toothed shafts, support VANOS adjustment unit with your hand. Grip on dihedron (1) and screw together at hexagon (2) alternately between exhaust and inlet sides in 1/2 turn increments.

Tighten down screw connection of toothed shaft on inlet and exhaust sides.

Tightening torque 10 N.m.

Scheme 388

Align radial piston pump to driver on spline hub.

Note. Picture shows a schematic representation.

Scheme 389

Press buttons 1 and 3 on special tool 12 6 050 simultaneously. The solenoid valves are activated and the air can escape from the hydraulic pistons of the VANOS adjustment unit.

Simultaneously push on VANOS adjustment unit until it rests on cylinder head.

CAUTION

If this position is not reached, check position of radial piston pump to driver and realign if necessary.

Scheme 390

Insert screws of VANOS adjustment unit and tighten down.

Scheme 391

Note. Check installed direction.

Install holder (4)

Scheme 392

Scheme 393

Insert screws (3) and secure holder (4) (do not tighten down screws (3) yet)
Install sliding rail (2).
Insert screws (1).
Tighten down screws (1) and screws (3).

Disconnect special tool 12 6 050 and special tool 12 6 410 and remove.

Insert screw connections in solenoid valves.

Scheme 394

Replace sealing rings of banjo bolt.

Insert banjo bolt but do not tighten down yet.

Scheme 395

Install bracket of oil line. Install screw and tighten down.

Scheme 396

Tighten down banjo bolt of oil line.

Tightening torque, refer to 11 36 9AZ in ENGINE - TIGHTENING TORQUES .

Assemble engine.

Scheme 397

CAUTION

11 36 582 Replacing Solenoid Valve On VANOS Adjustment Unit (S54)

E46 Only

Remove expansion rivets. Remove air duct (1).

Scheme 398

Scheme 398: 11 36 582 Replacing Solenoid Valve On VANOS Adjustment Unit (S54)

Disconnect plug connection (1) on solenoid valve.

CAUTION

Have a cleaning cloth ready. A small quantity of oil will emerge after the screws have been released. Make sure no oil runs onto belt drive. Remove any remnants of oil immediately with cleaning cloth.

Release screws and remove solenoid valve with sealing plate.

Scheme 399

Installation

Replace sealing plate (1). Sealing surfaces on solenoid valve and on VANOS adjustment unit clean and oil-free.

Scheme 400

11 40 000 Checking engine oil pressure (S50 / S54)

Special Tools Required

11 4 390
13 3 061
13 3 063

Note. When the main flow oil-filter cover is released, the oil flows from the oil-filter housing back into the sump.

Unfasten oil filter cover.

Scheme 401

Installation

Replace sealing ring.

Tightening torque, refer to 11 42 2AZ in ENGINE - TIGHTENING TORQUES .

Installation

Replace sealing ring in oil-filter cover and sealing ring on bolt.

Scheme 402

Check sealing rings (1 and 2) on special tool 11 4 390, replace if necessary.

Scheme 403

Insert special tool 11 4 390 and tighten down oil filter cover.

Scheme 404

Connect special tools 13 3 061/13 3 063.

Start engine and check engine oil pressure. Refer to ENGINE - TECHNICAL DATA .

Scheme 405

11 41 000 Removing and installing/replacing oil sump (S54)

Unscrew oil sump. Refer to 11 13 000 REMOVING AND INSTALLING, SEALING OR REPLACING OIL SUMP (S54) .

CAUTION

Left-hand threads. Unscrew nut (1).

Installation

Tightening torque, refer to 11 41 4AZ in ENGINE - TIGHTENING TORQUES .

Scheme 406

Press back chain tensioner (2).

Detach sprocket wheel (3) from teeth. Feed out sprocket wheel (3).

Installation

Align teeth of sprocket wheel and oil pump shaft to each other.

Scheme 407

Remove return pipe (1) and suction pipe (2).

Remove oil pump.

Installation

Replace O-ring on suction pipe (2).

Scheme 408

Installation

Check dowel sleeves (1) for damage and correct installation position.

Scheme 409

If necessary, remove control piston.

Press sleeve downwards with suitable drift.

CAUTION

The sleeve for the control plunger is under spring pressure.

Remove circlip.

Scheme 410

Installation

Scheme 411

Control plunger.
Spring.
Sleeve.
O-ring (replace).
Circlip.

11 51 000 Removing And Installing/Replacing Water Pump (S54)

Release water pump belt pulley.

Remove alternator drive belt. Refer to 11 28 010 REPLACING ALTERNATOR DRIVE BELT (S54) .

Remove pulley from water pump.

Remove coolant thermostat. Refer to 11 53 000 REMOVING AND INSTALLING/REPLACING COOLANT THERMOSTAT (S54) .

Scheme 412

Scheme 412: 11 51 000 Removing And Installing/Replacing Water Pump (S54)

E46 Only

Note. Pipe (1) is also screwed on exhaust side to cylinder head.

Release screws and remove pipe (1).

Installation

Scheme 413

Water pump is secured with 5 screws to engine block.

Release screw and remove water pump

Scheme 414

Installation

Check dowel pins (1) for damage and correct installation position.

Keep sealing faces clean and free of oil. Replace seal (2).

Scheme 415

Installation

Replace sealing ring on pipe (1).

Scheme 416

CAUTION

O-ring on pipe (1) can very easily be shorn off when water pump is fitted.

Coat sealing ring with water acting as antiseize agent and carefully fit water pump.

11 52 020 Removing And Installing/Replacing Fan Clutch (S52/S54/M52/M52TU/M54/M56)

Special Tools Required

11 5 030
11 5 040

If necessary, remove air duct.

Note. S54

Remove engine underguard and release fan cowl.

IMPORTANT

Left-hand threads.

Using special tool 11 5 030, grip pulley and unfasten cap nut from water pump using special tool 11 5 040.

If necessary, unfasten fan cowl.

Take the fan wheel with fan coupling off the water pump and remove.

Scheme 417

Installation

Tighten down fan impeller using special tool 11 5 040.

Tightening torque, refer to 11 52 1AZ in ENGINE - TIGHTENING TORQUES .

Note. When using special tool 11 5 040, 30 N.m. on the torque wrench scale are equivalent to a tightening torque of 40 N.m.

Scheme 418

Unfasten screws and detach fan from fan coupling.

Scheme 419

11 53 000 Removing And Installing/Replacing Coolant Thermostat (S54)

Remove fan clutch with fan impeller and fan cowl. Refer to 11 52 020 REMOVING AND INSTALLING/REPLACING FAN CLUTCH (S52 / S54 / M52 / M52TU / M54 / M56) and 17 11 031 REPLACING FAN COWL (S54) .

Remove coolant drain plug in engine block. Drain and dispose of coolant. See 17 11 509 FLUSHING RADIATOR

Installation

Replace sealing ring on drain plug.

Tightening torque, refer to 11 11 5AZ in ENGINE - TIGHTENING TORQUES .

Vent cooling system and check for leaks. Refer to 17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR LEAKS (S54) .

Remove intake filter housing with air-mass flow sensor. Refer to 13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING (S54) .

Scheme 420

Scheme 420: 11 53 000 Removing And Installing/Replacing Coolant Thermostat (S54)

Remove water hoses.

Open cable clamp (1).

Release screws on thermostat housing. Remove thermostat housing and thermostat.

Scheme 421

Installation

Keep sealing faces clean and free of oil.

Replace O-ring (1) on water pump and O-rings on connecting tube (2).

Coat O-rings on connecting tube (2) with water acting as antiseize agent.

CAUTION

O-rings on connecting tube (2) can very easily be shorn off.

Scheme 422

Installation

Preassemble thermostat (1) as shown in illustration on water pump.

Scheme 423

11 61 Removing And Installing/Replacing Servomotor For Throttle On Control Unit (M3 CSL)

Unfasten plug connection and disconnect.

Release screws (1).

Detach servomotor (2) from fresh air housing.

Scheme 424

Scheme 424: 11 61 Removing And Installing/Replacing Servomotor For Throttle On Control Unit (M3 CSL)

11 61 Removing And Installing/Replacing Throttle Switch On Control Unit (M3 CSL)

Open retainer and disconnect plug (1).

Loosen screws (2).

Remove throttle switch (3) from raw air housing.

Scheme 425

Scheme 425: 11 61 Removing And Installing/Replacing Throttle Switch On Control Unit (M3 CSL)

11 61 050 Removing And Installing Intake Air Manifold (S54)

Special Tools Required

11 9 160

Necessary preliminary tasks

Remove intake filter housing, refer to «13 71 000 REMOVING AND INSTALLING INTAKE FILTER HOUSING (S54)»(/bmw/m3/e46-1999-2006/remont/fuel-system/#fuel-system-repair__13-71-000-removing-and-installing) .

Note. Instructions for disconnecting and connecting battery. Refer to 12 00... INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Disconnect Negative Battery Lead.

Vehicles With SMG Transmissions Only

Open electronics box cover.
Detach relay (1) of hydraulic pump.
Disconnect line between expansion tank and hydraulic unit from intake manifold. IMPORTANT: Reinstall relay (1) of hydraulic pump only after connecting j line between expansion tank and hydraulic unit.

Scheme 426

E46 Only

Remove microfilter.

Scheme 427

E46 Only

Open cable duct on lower section of microfilter housing and feed out cable(s).

Scheme 428

E46 only

Release screws (1) and remove lower section of microfilter housing (2).

Scheme 429

Press locks.

Remove hose for engine vent.

Scheme 430

Gently raise lug (1) and slide holder upwards.

Scheme 431

Not Applicable To M3 CSL

Detach guide tube (1) for oil dipstick from intake air manifold.

Press locks on vacuum hose (2) and detach.

Scheme 432

Detach tank venting valve (1) from holder on intake air manifold.

Scheme 433

Release support bracket at front and rear from intake air manifold.

Scheme 434

Press lock. Detach hose (1) from intake air manifold.

Scheme 435

Disconnect hydraulic fluid connecting hose

Press locks.

Detach connecting hose to hydraulic unit tank connection.

Scheme 436

Place special tool 11 9 160 as shown in illustration on lugs of clamp.

Press clamp together until lock is opened.

Scheme 437

Installation

Replace clamps.

Preassemble clamps in installation position.

Catch (1) must be secured in lug (2).

Scheme 438

IMPORTANT

Use only original clamps. If hose clamps are used, there is the risk that the throttle control linkage will stop or jam and no longer return to the idle position.

Installation

Push intake air manifold with hose clamps (1) preassembled in installation position onto throttle assembly.

Scheme 439

Installation

Place special tool 11 9 160 as shown in illustration on lugs of clamp.

Press hose clamps together with special tool 11 9 160 until lock (1) engages.

Scheme 440

Press locks and detach condensate return (1).

Scheme 441

Note. For purposes of clarity, shown on removed engine.

IMPORTANT

A vacuum line (1) and a wiring harness (2) are clipped into place on the reverse side of the intake air manifold.

Scheme 442

Raise intake air manifold slightly and detach from throttle assembly.

Feed out vacuum line (1) and wiring harness (2).

Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (S54) .

11 62 140 Removing And Installing, Sealing/Replacing Both Exhaust Manifolds (S54)

E46 Only

Remove microfilter.

Open cable duct on lower section of microfilter housing (2) and feed out cable(s).

Release screws (1) and remove lower section of microfilter housing (2).

Scheme 443

Scheme 443: 11 62 140 Removing And Installing, Sealing/Replacing Both Exhaust Manifolds (S54)

Remove expansion rivets. Remove air duct (1).

Scheme 444

Remove hose (1) for engine vent.

Remove sealing cap (2).

Remove ignition coil cover.

Scheme 445

Note. The plug housings of the oxygen sensors for cylinders 1 to 3 and 4 to 6 are different.

Unclip plug housing (1) from mounting.

Disconnect plug connections of oxygen sensors.

Scheme 446

E46 Only

Instructions for working on cooling system, refer to 17 00... INSTRUCTIONS FOR WORKING ON COOLING SYSTEM. .

Drain coolant.

Pull locks.

Remove hose (1).

Scheme 447

Feed oxygen sensor cables out of shield plate of exhaust manifold.

Note. Fig. shows US version.

Scheme 448

Remove check valve from cylinder head.

Installation

Replace the seal and nuts.

Remove exhaust manifold shield plate and A/C system hoses.

Remove engine splash guard.

E46 Only

Remove reinforcement plate.

CAUTION

The article 51 71 374 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE ON FRONT AXLE SUPPORT (M3) contains important installation instructions.

ECE version

Remove catalytic converter. Refer to 18 32 005 REMOVING AND INSTALLING/REPLACING CATALYTIC CONVERTER (S54) .

US version

Remove front exhaust system (front pipes).

Note. The oxygen sensors are in danger of being damaged when the exhaust manifolds are removed and installed.

Remove oxygen sensors from exhaust manifolds.

Note. Exhaust manifolds (1 and 2) cannot be removed individually.

Detach exhaust manifold (1) from cylinder head and place on engine support arm.

Detach exhaust manifold (2) from cylinder head. Feed out exhaust manifolds (1 and 2) together.

Scheme 449

Installation

Clean sealing faces, replace gaskets.

Coat threads with copper paste.

Replace nuts.

Tightening torque, refer to 11 62 1AZ in ENGINE - TIGHTENING TORQUES .

CAUTION

Ensure cables are exactly routed.

Installation

Clip cables of oxygen sensors into mounts on shield plate of exhaust manifold.

Note. Fig. shows US version.

Scheme 450

11 78 510 Replacing Both Oxygen Control Sensors (S54)

Special Tools Required

11 7 030
11 9 150

Read out fault memory, clear if necessary. Refer to 13 00 002 CHECKING FUNCTION OF DIGITAL ENGINE ELECTRONICS (DME) .

E46 Only

Remove microfilter.

Open cable duct on lower section of microfilter housing (2) and feed out cable.

Release screws (1) and remove lower section of microfilter housing (2).

Scheme 451

E46 Only

Lever out expansion rivets. Remove air duct (1).

Scheme 452

Remove hose (1) for engine vent.

Remove sealing cap (2).

Remove ignition coil cover.

Scheme 453

Note. The plug housings of the oxygen sensors for cylinders 1 to 3 and 4 to 6 are different.

Unclip plug housing (1) from mounting.

Disconnect plug connections of oxygen sensors.

Scheme 454

Feed oxygen sensor cables out of shield plate of exhaust manifold.

Installation

Clip cables of oxygen sensors into mounts on shield plate of exhaust manifold.

Scheme 455

CAUTION

Ensure cables are exactly routed.

Note. Fig. shows US version.

Remove underbody protection.

E46 Only

Remove reinforcement plate.

CAUTION

The article 51 71 374 REMOVING AND INSTALLING / REPLACING REINFORCEMENT PLATE ON FRONT AXLE SUPPORT (M3) contains important installation instructions.

The oxygen sensors for cylinders 1 to 3 and 4 to 6 are different.

Mark oxygen sensors so as not to mix sensors up at a later J stage.

Detach oxygen sensors with special tool 11 7 030 in conjunction with special tool 11 9 150.

Scheme 456

Remove oxygen sensor from cylinders 1 to 3.
Remove oxygen sensor from cylinders 4 to 6.

Installation

The threads of new oxygen monitor sensors are already coated with Never Seez Compound.

If an oxygen monitor sensor is used again, apply a thin and even coat of Never Seez Compound to the thread only.

Do not clean that part of the oxygen sensor which projects into the exhaust system branch and do not allow it to come into contact with lubricants.

Installation

When special tool 11 9 150 is used in conjunction with special tool 11 7 030, 47 N.m on the dial on the torque wrench corresponds to an actual tightening torque of 50 N.m.

For final tightening of oxygen sensors, fit torque wrench and special tool (11 7 030/11 9 150) as illustrated.

Tightening torque, refer to 11 78 1AZ in ENGINE - TIGHTENING TORQUES .

Install oxygen sensor for cylinders 4 to 6 and tighten down.
Install oxygen sensor for cylinders 1 to 3 and tighten down.

Cover oxygen sensors when applying underseal.

Pay attention to cable routing for oxygen sensors.

Scheme 457

11 78 613 Replacing Both Oxygen Monitor Sensors (S54)

Special Tools Required

11 7 020
11 7 030
11 9 150

Refer to 13 00 002 CHECKING FUNCTION OF DIGITAL ENGINE ELECTRONICS (DME) .

US Version

In the US version, the oxygen monitor sensors are installed in the exhaust manifolds.

Cylinders 1 to 3: Release monitor sensor with special

tool 11 9 150 in conjunction with special tool 11 7 030 and tighten down.

Installation

When special tool 11 9 150 is used in conjunction with special tool 11 7 030, 47 N.m on the torque wrench dial corresponds to an actual tightening torque of 50 N.m.

Cylinders 4 to 6: Release monitor sensor with special tool 11 7 020 and tighten down.

Tightening torque, refer to 11 78 1AZ in ENGINE - TIGHTENING TORQUES .

ECE Version

Remove catalytic converter. Refer to 18 32 005 REMOVING AND INSTALLING/REPLACING CATALYTIC CONVERTER (S54) .

Unclip oxygen monitor sensor cable from holder.

To release and tighten down oxygen monitor sensors (1), use special tool 11 7 020 or special tool 11 7 030.

Tightening torque, refer to 11 78 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 458

Installation

The threads of new oxygen monitor sensors are already coated with Never Seez Compound.

If an oxygen monitor sensor is used again, apply a thin and even coat of Never Seez Compound to the thread only.

Do not clean that part of the oxygen sensor which projects into the exhaust system branch and do not allow it to come into contact with lubricants.

Cover oxygen monitor sensor when applying underseal. Pay attention to cable routing for oxygen monitor sensor.

Engine - Repair (s54) BMW M3 E46

00 00 250 BMW Engine Oil Service Incl. Supplementary Service (S54)

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

11 00 039 Checking Compression Of All Cylinders (S54)

Scheme 7

11 00 045 Checking Absolute Compression Of All Cylinders

Scheme 8

11 00 050 Removing and installing engine (S54)

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

11 12 000 Removing And Installing, Sealing Cylinder Head Cover (S54)

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

11 12 100 Removing And Installing/Sealing Cylinder Head (S54)

Removal

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Installation

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

11 12 101 Replacing Cylinder Head Gasket (S50 S54)

11 12 503 Disassembling And Assembling Cylinder Head - Cylinder Head Removed (S54)

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

11 12 527 Remachining A Valve Seat - Cylinder Head Disassembled (S50/S54)

Scheme 58

Scheme 59

11 12 595 Checking A Valve Guide For Wear - Valve Removed (S50/S54)

Scheme 60

11 12 729 Checking Cylinder Head For Leaks - Cylinder Head Removed (S54)

Scheme 61

Scheme 62

11 13 000 Removing And Installing, Sealing Or Replacing Oil Sump (S54)

Scheme 63

Scheme 64

Scheme 65

Scheme 66