Engine - Repair (N63): Other BMW X6 E71

00 Danger of poisoning if oil is ingested/absorbed through the skin

Danger of poisoning!

Ingesting oil or absorbing through the skin may cause poisoning!

Possible symptoms are

1. Headaches
2. Dizziness
3. Stomach aches
4. Vomiting
5. Diarrhoea
6. Cramps/fits
7. Unconsciousness

Protective measures/rules of conduct

1. Pour oil only into appropriately marked containers
2. Do not pour oil into drinking vessels (drinks bottles, glasses, cups or mugs)
3. Observe country-specific safety regulations

First aid measures

1. Do not induce vomiting. If the person affected is still conscious, he/she must rinse out their mouth with water, drink plenty of water and consult a doctor immediately. If the person affected is unconscious, do not administer anything by mouth, place the person in the recovery position and seek immediate medical attention.

00 Risk of injury if oil comes into contact with eyes and skin

Danger of injury!

Contact with eyes or skin may result in injury!

Possible symptoms are

1. Impaired sight
2. Irritation of the eyes
3. Reddening of the skin
4. Rough and cracked skin

1. Wear protective goggles
2. Wear oil-resistant protective gloves
3. Observe country-specific safety regulations

1. Eye contact: Rinse eyes immediately with plenty of water for at least 15 minutes; if available, use an eye-rinsing bottle. If irritation of the eyes persists, consult a doctor.
2. Skin contact: Wash off with soap and water immediately. If irritation persists, consult a doctor.

Note. Do not use solvents/thinners.

00 Safety instructions for handling oil

Recycling

Observe country-specific waste-disposal regulations.

Measures if oil is unintentionally released

1. Personal precautionary measures: Danger of slipping! Keep non-involved persons away from the work area. Wear personal protective clothing/equipment.
2. Environmental protection measures: Prevent oil from draining into drain channels, sewerage systems, pits, cellars, water and the ground.
3. Limiting spread: Use oil blocks to prevent the surface spread of oil.
4. Cleaning procedure: Bind and dispose of escaped oil with nonflammable absorbents.

Note. Do not flush oil away with water or aqueous cleaning agents.

00 Safety information for working on vehicles with automatic engine start-stop function (MSA)

Observe safety precautions when working on MSA vehicles

Before carrying out practical work on the engine, always ensure that the MSA functionality is deactivated so as to prevent automatic engine starting while work is being carried out in the engine compartment.

MSA function is deactivated by

1. Deactivate MSA by means of button (1) in passenger compartment
2. Open seat belt buckle and driver's door
3. Open engine bonnet/hood and ensure that engine hood/bonnet contact is not in workshop mode

1. Workshop mode
2. Basic setting (engine hood/bonnet open)

B = 7 mm

To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the hood/bonnet contact up to the limit position before starting work and slowly release.

Scheme 81

When working with diagnosis tools

1. Observe instructions in diagnosis tool

Removing engine cover (N63)

Raise engine cover (1) at the four points (see arrows) and in upward direction.

Scheme 82

Check lock (1) for damage.

Check lock (2) for damage.

Scheme 83

Apply a light coating of antiseize agent to take-ups (1).

Scheme 84

Assemble engine

11 00... Service - engine oil (N63)

Special tools required

1. 11 9 240

See ENGINE - SPECIAL TOOLS (N54, N63) .

Recycling

Catch and dispose of drained engine oil in a suitable container.

Observe country-specific waste-disposal regulations.

Release screw plug (1) on oil filter cap.

Remove screw plug (2) from oil sump and drain engine oil.

Scheme 85

Release oil filter cap (1) with special tool 11 9 240.

Tightening torque 11 42 1AZ, see 11 42 OIL FILTER AND PIPES

Scheme 86

Installation

Replace oil filter element (3) and sealing rings (1 to 2) .

Installation

Moisten sealing ring (2) with engine oil.

Insert oil filter element (3) into oil filter cap.

11 00 050 Removing and installing/replacing engine (N63)

Special tools required

1. 11 0 020
2. 13 5 162

See ENGINE - SPECIAL TOOLS (N54, N63) .

See FUEL SYSTEM - SPECIAL TOOLS .

Necessary preliminary tasks

1. Clamp off battery . See «BATTERY»(ref-351441-S18688541382009122100000)
2. Move engine hood/bonnet into service position
3. Remove ground cable
4. Remove mounting bracket for windscreen wiper system. See «61 61 270 REMOVING AND INSTALLING OR REPLACING BRACKET FOR WINDSCREEN WIPER SYSTEM COMPLETE WITH MOTOR»(ref-351441-S36704501942009122100000)
5. Remove «RADIATOR AIR GUIDE»(ref-351461-S40549986942009122100000)
6. Remove «MODULE CARRIER (N63)»(ref-349799-S37367015802009121000000)
7. Remove both intake filter housings . See «13 71 030 REMOVING AND INSTALLING BOTH INTAKE FILTER HOUSINGS (N63)»(ref-349797-S00938821222009121000000) .
8. Disconnect coolant hoses from engine
9. Disconnect coolant hoses from intercooler expansion tank
10. Disconnect line from tank vent valve
11. Release feed and return lines for engine oil cooler. See «OIL COOLER LINES»(ref-349799-S25106873822009121000000) .
12. Release suction line and return line on oil reservoir. See «OIL COOLER LINES»(ref-349799-S25106873822009121000000) .
13. Release power steering pump with bracket. See «32 41 033 REMOVING AND INSTALLING POWER STEERING PUMP FOR POWER STEERING GEAR WITH ACTIVE FRONT STEERING (N63)»(ref-351455-S31023533002010030300000) or «32 41 037 REMOVING AND INSTALLING/REPLACING POWER STEERING PUMP FOR POWER STEERING GEAR WITH DYNAMIC DRIVE (N63)»(ref-351455-S22642062662010030300000) .
14. Remove transmission . See «24 00 023 REMOVING AND INSTALLING AUTOMATIC TRANSMISSION (GA6HP26Z) (N63)»(ref-351450-S00588013532010033100000) .
15. Remove front output shafts . See «OUTPUT SHAFT»(ref-351453-S08571858702009122100000)
16. Remove left and right holders of front cross-strut. See «31 12 043 REMOVING AND INSTALLING/REPLACING COMPLETE FRONT LEFT OR RIGHT SPRING STRUT HOLDER»(ref-351453-S05694378302009122100000) . Release engine wiring harness from electronics box and secure on engine against falling off. Unlock all plugs (1) of DME control unit and disconnect. Unlock plug on electronics box fan and disconnect. Unlock and detach terminal strip (2). Unlock all plugs on plug strip (3) and detach. Unlock plug strip (3) and remove towards top.

Scheme 87

Release screws and remove retaining bar (1).

Unlock upper section (2) of partition seal in direction of arrow and remove.

Release grommets (3) for wiring harnesses from lower section of partition seal and from electronics box.

Installation

Make sure grommets are correctly seated so as to prevent ingress of moisture.

Scheme 88

Open cover.

Release screw (1).

Tightening torque 13 71 8AZ, see 13 71 AIR INTAKE DUCT

Remove battery positive lead (2) from battery positive terminal.

Scheme 89

Unlock and detach vacuum line (1) from vacuum pump.

Scheme 90

Release screws (1).

Remove double pipe (2).

Installation

Replace sealing rings and moisten with refrigerant oil.

Tightening torque 64 53 5AZ, see CONDENSER AND DRYER

Scheme 91

Unlock water pipe (1) on heater end plate and detach.

Scheme 92

Unlock and disconnect fuel feed line (1), seal off with special tool 13 5 160.

Seal off fuel feed line (2) with special tool 13 5 162.

Scheme 93

Release screws (1) on engine mount on left and right.

Tightening torque 22 11 2AZ, see 22 11 ENGINE SUSPENSION

Scheme 94

Suspend special tool from lifting eyes (1) at front and rear.

Lift out engine with special tool 11 0 020.

Picture shows (F01).

Scheme 95

Mount engine on assembly stand.

Assemble engine.

Top up coolant and vent cooling system. See 17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR WATER LEAKS (N63) .

Check cooling system for leaks. See 17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR WATER LEAKS (N63) .

11 00 598 Removing and installing engine on front axle E70 E71 (N63/S63)

Necessary preliminary tasks

1. Remove front axle with engine and transmission.

Release screws. Installation note: Replace screws. Tightening torque 26 11 9AZ.

Scheme 96

Slide propeller shaft towards rear and remove.

Scheme 97

Installation note: Slide propeller shaft fully towards rear. Sealing cup (1) must snap audibly into place and rest entirely on dust guard (2).

Scheme 98

Slacken nut (1) two to three thread turns. If necessary, replace lower section 31 2 242 with lower section 31 2 247. Press control arm (2) with special tool 31 2 240) off swivel bearing. Unscrew nut (1) and remove control arm (2) from swivel bearing.

Installation note: Keep wishbone to swivel bearing connection clean and free from oil and grease. Replace self-locking nut. Tightening torque 31 12 4AZ.

Scheme 99

Slacken nut (1) two to three thread turns. If necessary, replace lower section 31 2 242 with lower section 31 2 247. Press tension strut (2) with special tool 31 2 240 off swivel bearing. Unscrew nut (1) and remove tension strut (2) from swivel bearing.

Installation note: Keep tension strut to swivel bearing connection clean and free from oil and grease. Replace self-locking nut. Tightening torque 31 12 2AZ. .

Scheme 100

Slacken nut (1) two to three thread turns. If necessary, replace lower section 31 2 242 with lower section 31 2 246. Press track rod end (2) with special tool 31 2 240 off swivel bearing. Unscrew nut (1) and remove track rod end (2) from swivel bearing.

Installation note: Keep track rod end to swivel bearing connection clean and free from oil and grease. Replace self-locking nut. Tightening torque 32 21 3AZ.

Scheme 101

Release screws (1). Slacken nut (2). Pull off expandable hose (3) of Adaptive Drive 1st part.

Recycling: Catch and dispose of escaping oil with auxiliary materials.

Scheme 102

Release screws (1). Disconnect line (2) part 1.

Recycling: Catch and dispose of escaping oil with auxiliary materials.

Scheme 103

Release screw and remove oil lines (2). Tightening torque, 17 22 4AZ.

Installation note: Replace sealing rings.

Scheme 104

Recycling: Catch and dispose of escaping oil with auxiliary materials.

Remove swivel bearing (1) with brake disc and drive shaft (3) with the aid of a workshop crane (2). Do not bend output shaft (3) too far, note deflection angle. The illustration shows the procedure on the left swivel bearing; the procedure on the right swivel bearing is identical.

Scheme 105

Screw fixtures (20) onto table lift at a suitable location. Move screw adapter (30) with plate (80) up against the transmission oil sump (1).

Scheme 106

Remove cover on transmission.

Scheme 107

Crank engine at central bolt. Release converter bolts (1).

Scheme 108

Press special tool 24 1 380 together and insert into recess in transmission housing.

Scheme 109

Release screw (1). Release hydraulic lines (2).

Installation note: Replace sealing rings.

Scheme 110

Recycling: Catch and dispose of escaping oil with auxiliary materials.

Release screw (1). Lay ground strap (2) to one side.

Scheme 111

Unclip the transmission wiring harness from its holders (2 3 4 and 5). Pull off the transmission wiring harness from the transmission at the holder (1).

Scheme 112

Take off the transmission connector (1). Unclip the transmission wiring harness from holders (2).

Scheme 113

Release all screws on transmission. Tightening torque 24 00 1AZ.

Installation note: Screws have different lengths. Note installation position.

Scheme 114

Slightly raise engine with workshop crane and special tool 11 0 020. This simplifies removal and installation of transmission.

Scheme 115

Recycling: Capture emerging transmission oil with a suitable drip tray (1).

Disconnect transmission (2) from engine in the direction of the arrow. Pictures show N74.

Scheme 116

Unscrew nuts (1). Raise engine approx. 10 mm with cross-member.

Installation note: Replace self-locking nuts. Tightening torque 22 11 2AZ.

Lift engine (1) with workshop crane (2) and special tool 11 0 020 from front axle. Mount engine on assembly stand.

Scheme 117

11 12 005 Removing and installing/sealing left cylinder head cover (N63)

Special tools required

1. 11 4 470

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove «acoustic cover»(ref-349795-S18125844022010030200000)
2. Clamp off battery negative terminal . See «BATTERY»(ref-351441-S18688541382009122100000) .
3. Remove left intercooler . See «17 51 001 REMOVING AND INSTALLING/REPLACING LEFT INTERCOOLER (N63)»(ref-349799-S11197747742009121000000) or «17 51 001 REMOVING AND INSTALLING/REPLACING RIGHT INTERCOOLER (N63)»(ref-349799-S04939739542009121000000) .
4. Remove intake filter housing . See «13 71 030 REMOVING AND INSTALLING BOTH INTAKE FILTER HOUSINGS (N63)»(ref-349797-S00938821222009121000000) .
5. Remove expansion tank . See «ENGINE RADIATOR»(ref-349799-S04571686442009121000000) .
6. Remove coolant pipe from cylinder head cover (E71 only)
7. Remove coolant valve for heater feed line
8. Disconnect fuel feed line . See «13 53 332 REMOVING AND INSTALLING/REPLACING FEED LINE (N63)»(ref-349797-S17657261182009121000000) .
9. Detach wiring harness for injectors and lay to one side
10. Remove ignition coils , cylinders 5-8. See «12 13 511 REPLACING IGNITION COILS (N63)»(ref-349796-S25780301562009121000000) .
11. Remove injectors , cylinders 5-8. See «13 53 310 REMOVING AND INSTALLING/REPLACING AN INJECTOR (N63)»(ref-349797-S08167307252009121000000) .
12. Remove high-pressure pump . See «13 51 065 REMOVING AND INSTALLING/REPLACING LEFT HIGH-PRESSURE FUEL PUMP (N63)»(ref-349797-S00637477832009121000000) or «13 51 070 REMOVING AND INSTALLING/REPLACING RIGHT HIGH-PRESSURE FUEL PUMP (N63)»(ref-349797-S05860536602009121000000) . Release bolts in sequence (17 to 1). Remove cylinder head cover.

Scheme 118

Clean sealing face (1) with special tool 11 4 470.

Installation

Replace seal (2) .

Scheme 119

Installation

Replace profile gasket of cylinder head cover .

Scheme 120

Installation

It is important to join screw (1) for exact positioning of the camshaft sensors.

Fit cylinder head cover.

Position screw (1).

Release screw (1) by 90°.

Scheme 121

Secure cylinder head cover in sequence (1 to 17) in two work steps.

Tightening torque 11 12 3AZ, see CYLINDER HEAD WITH COVER

Assemble engine.

11 12 006 Removing and installing/sealing right cylinder head cover (N63)

Special tools required

1. 11 4 470

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove «acoustic cover»(ref-349795-S18125844022010030200000)
2. Disconnect battery negative terminal . See «BATTERY»(ref-351441-S18688541382009122100000) .
3. Release battery positive terminal
4. Remove right intercooler . See «17 51 001 REMOVING AND INSTALLING/REPLACING LEFT INTERCOOLER (N63)»(ref-349799-S11197747742009121000000) or «17 51 001 REMOVING AND INSTALLING/REPLACING RIGHT INTERCOOLER (N63)»(ref-349799-S04939739542009121000000) .
5. Remove intake filter housing . See «13 71 030 REMOVING AND INSTALLING BOTH INTAKE FILTER HOUSINGS (N63)»(ref-349797-S00938821222009121000000) .
6. Disconnect fuel feed line . See «13 53 332 REMOVING AND INSTALLING/REPLACING FEED LINE (N63)»(ref-349797-S17657261182009121000000) .
7. Detach wiring harness for injectors and lay to one side.
8. Remove ignition coils , cylinders 1-4. See «12 13 511 REPLACING IGNITION COILS (N63)»(ref-349796-S25780301562009121000000) .
9. Remove injectors , cylinders 1-4. See «13 53 310 REMOVING AND INSTALLING/REPLACING AN INJECTOR (N63)»(ref-349797-S08167307252009121000000) .
10. Remove high-pressure pump . See «13 51 065 REMOVING AND INSTALLING/REPLACING LEFT HIGH-PRESSURE FUEL PUMP (N63)»(ref-349797-S00637477832009121000000) or «13 51 070 REMOVING AND INSTALLING/REPLACING RIGHT HIGH-PRESSURE FUEL PUMP (N63)»(ref-349797-S05860536602009121000000) .

Release screws (1).

Tightening torque 11 12 9AZ, see CYLINDER HEAD WITH COVER

Remove oil filler neck (2).

Installation

Replace sealing ring .

Scheme 122

Release bolts in sequence (17 to 1).

Remove cylinder head cover.

Scheme 123

Clean sealing face (1) with special tool 11 4 470.

Installation

Replace seal (2) .

Scheme 124

Installation

Replace profile gasket of cylinder head cover .

Installation

It is important to join screw (1) for exact positioning of the camshaft sensors.

Fit cylinder head cover.

Position screw (1).

Release screw (1) by 90°.

Scheme 125

Secure cylinder head cover in sequence (1 to 17) in two work steps.

Tightening torque 11 12 3AZ, see CYLINDER HEAD WITH COVER

Assemble engine.

11 12 105 Removing and installing left cylinder head (N63)

Special tools required

1. 11 4 470

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Check «timing»(ref-349795-S32155175162009121000000) .
2. Remove left «inlet and exhaust adjustment unit»(ref-349795-S18155197382009121000000)

Release screw (1).

Note. Guide rail is loose from cylinder head.

Scheme 126

Release bolts (1) at front from cylinder head.

Scheme 127

Release cylinder head bolts in sequence (10 to 1).

Remove all cylinder head bolts with washers.

Note. For purposes of clarity, the graphic shows the camshafts removed. Clean sealing faces of cylinder head and crankcase; if necessary, remove gasket debris with special tool 11 4 470. Make sure no gasket remnants drop into oil and cooling channels.

Check cylinder head for leaks.

Check cylinder head sealing face for surface evenness.

Coat joint between engine block and timing case cover with Drei Bond 1209).

Note. Graphic shows an N62 engine by way of example.

Scheme 128

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

Installation

Replace cylinder head gasket (2) .

Fit new cylinder head gasket (2).

Scheme 129

Note. Graphic corresponds to cylinders 1-4.

Put the cylinder head on.

Do not wash off bolt coating.

Installation

Fit new cylinder head screws .

Insert new cylinder head bolts and initially tighten so that they are free of play.

Tighten down cylinder head bolts in sequence 1 - 10.

Tightening torque 11 12 1AZ, see CYLINDER HEAD WITH COVER

Scheme 130

Install and tighten down bolts (1) between cylinder head and timing case cover.

Tightening torque 11 12 2AZ, see CYLINDER HEAD WITH COVER

Insert screw (1) of guide rail and tighten down.

Tightening torque 11 31 3AZ, see 11 31 CAMSHAFT

If necessary, install camshafts .

Install left inlet and exhaust adjustment unit .

Assemble engine.

11 12 106 Removing and installing right cylinder head (N63)

Special tools required

1. 11 4 470

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Check «timing»(ref-349795-S32155175162009121000000) .
2. Remove inlet and exhaust «adjustment unit»(ref-349795-S17923751272009121000000) on right side .

Release screw (1).

Note. Guide rail is loose from cylinder head.

Release bolts (1) at front from cylinder head.

Release cylinder head bolts in sequence (10 to 1).

Remove all cylinder head bolts with washers.

Note. Shown without camshafts for purposes of clarity.

Scheme 131

Clean sealing faces of cylinder head and crankcase; if necessary, remove gasket debris with special tool 11 4 470.

Make sure no gasket debris drops into the oil and coolant ducts.

Threaded bores in engine block must be free of dirt and oil (risk of cracking) .

Check cylinder head for leaks .

Check cylinder head sealing face for surface evenness.

Coat joint between engine block and timing case cover with Drei Bond 1209).

Note. Illustrations show N62.

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

Fit new cylinder head gasket (2).

Put the cylinder head on.

Do not wash off bolt coating.

Insert new cylinder head bolts and initially tighten so that they are free of play.

Tighten down the cylinder-head bolts in order 1... 10.

Tightening torque: 11 12 1AZ, see CYLINDER HEAD WITH COVER

Install and tighten down bolts (1) between cylinder head and timing case cover.

Tightening torque: 11 12 2AZ, see CYLINDER HEAD WITH COVER

Insert screw (1) of guide rail and tighten down.

Tightening torque: 11 31 3AZ, see 11 31 CAMSHAFT

If necessary, install camshafts .

Install inlet and exhaust adjustment unit on left side .

Assemble engine.

11 12 112 Replacing both cylinder head gaskets (N63)

Necessary preliminary tasks

1. Remove left «cylinder head»(ref-349795-S14364938732009121000000)
2. Remove right «cylinder head»(ref-349795-S30557625472009121000000)

Installation

The cylinder head gaskets (2) for cylinders 1-4 and 5-8 are identical.

There is no marking (TOP).

Cylinder head gasket (2) must depending on its styling be correctly positioned on the timing chain case.

Repair gasket (+REP) is 0.3 mm thicker.

Check cylinder head for surface evenness.

Scheme 132

Assemble engine.

11 12 719 Grinding cylinder head sealing surface (N63)

Necessary preliminary tasks

1. Remove «cylinder head (right)»(ref-349795-S30557625472009121000000) or «cylinder head (left)»(ref-349795-S14364938732009121000000) .

11 12 729 Checking cylinder head for watertightness (N63)

Special tools required

1. 00 9 250
2. 11 8 080
3. 11 8 081
4. 11 8 082
5. 11 8 083

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove «left cylinder head»(ref-349795-S14364938732009121000000) .
2. Remove «right cylinder head»(ref-349795-S30557625472009121000000) .
3. Remove all «valves»(ref-349795-S16100928912009121000000) .

Note. Special tool kit 11 8 080 can be used for cylinder bank 1 to 4 and cylinder bank 5 to 8. Position special tool 11 8 081 on cylinder head.

Scheme 133

Insert special tool 11 8 083 and tighten in sequence (1 to 10) in several stages.

Tightening torque: 25 Nm

Scheme 134

Remove vent screw (1).

Tightening torque: 11 12 8AZ, see CYLINDER HEAD WITH COVER

Installation

Replace sealing ring.

Scheme 135

Scheme 136

Note. If necessary, add cleaning agent to water bath. Assemble engine.

11 13 010 Removing and installing/replacing upper oil sump section (N63)

Special tools required

1. 11 9 240

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Drain off engine oil
2. Secure engine in «installation position»(ref-349795-S21994849402009121000000)
3. Lower front axle . See «31 11 506 LOWERING/RAISING FRONT AXLE CARRIER (UNIVERSAL LIFTER)»(ref-351453-S15840436472009122100000) .
4. Remove front differential . See «31 50 001 REMOVING AND INSTALLING/REPLACING FRONT DIFFERENTIAL»(ref-351453-S09194112142009122100000) .
5. Remove lower oil «sump»(ref-349795-S07846437932009121000000) section
6. Release «FEED AND RETURN LINES»(ref-349799-S03315150912009121000000) on oil filter
7. Release holders of supply/return lines on oil sump
8. Detach plug from oil pressure switch
9. Unclip wiring harness on oil sump Remove oil filter cover with oil filter (1) with special tool 11 9 240. Tightening torque: 11 42 1AZ, see «11 42 OIL FILTER AND PIPES»(ref-351668-S38696325112009122800000)

Release screws (2).

Tightening torque: 11 41 1AZ, see 11 41 OIL PUMP WITH STRAINER AND DRIVE

Scheme 137

Release bolts in area of line (1).

Scheme 138

Release bolts in area of line (1).

Scheme 139

Release bolts in area of line (2).

Tightening torque 11 13 2AZ, see OIL SUMP

Release 4 bolts on transmission side.

Tightening torque 24 00 1AZ, see 24 00 TRANSMISSION IN GENERAL

Remove upper oil sump section (1).

Scheme 140

Installation

Free sealing faces of seal debris and clean.

Replace seal.

Modify oil pressure switch if replacing oil sump.

Assemble engine.

11 13 020 Removing and installing/replacing lower oil sump section (N63)

Necessary preliminary tasks

1. Remove reinforcement plate . See «31 10 010 REMOVING AND INSTALLING/REPLACING REINFORCEMENT PLATE»(ref-351453-S32119490602009122100000) .
2. «Remove oil drain plug»(ref-349795-S20762240782009121000000) and drain engine oil.

Unlock plug connection (1) on oil level sensor and disconnect.

Release screws (2) along line.

Tightening torque 11 13 2AZ, see OIL SUMP

Remove lower oil sump section (3).

Installation

Clean sealing surfaces.

Replace seal.

Replace bolts.

When replacing oil sump bottom section

Convert oil level sensor.

Replace sealing ring.

Scheme 141

Timing case cover, cylinders 5-8

Necessary preliminary tasks

1. Remove both «solenoid valves»(ref-349795-S20997634292009121000000) on left side

Release screws (1).

Tightening torque 11 14 3AZ, see 11 14 CASE COVERS

Remove timing case cover (2).

Installation

Replace seal .

Scheme 142

Assemble engine.

Timing case cover, cylinders 1-4

Necessary preliminary tasks

1. Remove both «solenoid valves»(ref-349795-S17923751272009121000000) on right side

Release screws (1).

Tightening torque 11 14 3AZ, see 11 14 CASE COVERS

Remove timing case cover (2).

Installation

Replace seal .

Scheme 143

Assemble engine.

11 14 110 Removing and installing lower timing case cover (N63)

Special tools required

1. 11 4 470

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove «engine»(ref-349795-S06065388982009121000000) .
2. Remove both «left cylinder head»(ref-349795-S14364938732009121000000) and «right cylinder head»(ref-349795-S30557625472009121000000) .
3. Remove lower oil «sump»(ref-349795-S30951694292009121000000) section .
4. Remove upper oil «sump»(ref-349795-S30951694292009121000000) section .
5. Remove alternator «belt tensioner»(ref-349795-S38778776492009121000000) .
6. Remove «vibration damper»(ref-349795-S23292670432009121000000) .
7. Remove «coolant pump»(ref-349795-S09752782762009121000000) .
8. Remove alternator . See «12 31 020 REMOVING AND INSTALLING OR REPLACING ALTERNATOR (N63)»(ref-349796-S12957128002009121000000) .
9. Remove A/C compressor . See «64 52 521 REPLACING A/C SYSTEM COMPRESSOR (N63)»(ref-351466-S00526109522010031100000) .
10. Remove hub for «vibration damper»(ref-349795-S24291936922009121000000) Release screws along lines (1). Remove timing case cover (2) towards front. Clean sealing faces with special tool 11 4 470.

Scheme 144

Note. Check jump guard for damage. Release screw (1). Tightening torque 11 14 1AZ, see 11 14 CASE COVERS Remove jump guard (2).

Scheme 145

Clean sealing faces with special tool 11 4 470.

Installation

Preposition all bolts in timing case cover.

Replace beaded metal gaskets (1, 2 and 3) .

Scheme 146

Fit timing case cover (2).

Initially tighten all bolts to approx. 5 Nm.

Fully tighten all bolts in alternate sequence.

Tightening torque 11 14 2AZ, see 11 14 CASE COVERS

Installation

Wait for PU material to emerge at sealing joints.

Carefully wipe off protruding PU material.

Replace radial shaft seal in timing case cover at bottom .

Assemble engine.

11 14 141 Replacing radial shaft seal in lower timing case cover (N63)

Special tools required

1. 11 9 410
2. 11 9 420

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Removing «vibration damper»(ref-349795-S24291936922009121000000)

Position all levers (2) horizontally to pull off radial shaft seal (1).

Turn back spindle of special tool 11 9 410 until all levers (2) can be positioned on sealing lip.

Scheme 147

Turn all levers (2) so that they grip behind radial shaft seal (1).

Turn spindle (3) on special tool 11 9 410 to remove radial shaft seal (1).

Scheme 148

Note. Radial shaft seal (1) may only be supported with "support sleeve" (2).

If the radial shaft seal (1) is stored for more than six months without the support sleeve (2), its operational reliability will no longer be guaranteed.

Radial shaft seal (1) must not be reused in this eventuality!

Scheme 149

Remove support sleeve (2) from radial shaft seal (1).

Fit radial shaft seal (1) on lower timing case cover.

Scheme 150

Using special tool 11 9 420 and central bolt (3), screw radial shaft seal into lower timing case cover until flush.

Scheme 151

Assemble engine.

11 14 151 Replacing crankshaft radial seal on transmission side (N63)

Necessary preliminary tasks

1. Drain off «engine oil»(ref-349795-S20762240782009121000000)
2. Remove «flywheel»(ref-349795-S30768805762009121000000)

Release screws (1).

Release screws (2).

Carefully remove end cover with crankshaft radial seal.

Scheme 152

Note. Support sleeve (2) is included in scope of delivery. If the crankshaft radial seal (1) is stored for more than six months without the support sleeve (2), its operational reliability will no longer be guaranteed. Crankshaft radial seal (1) must not be reused in this eventuality! Support sleeve (2) remains in the crankshaft radial seal (1) and is used as a slip sleeve during subsequently described installation.

When the crankshaft radial seal is installed, only the support sleeve included in the scope of delivery may be used as a slip sleeve.

Scheme 153

Installation

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

Clean sealing face (2) so that it is free from oil and grease.

Coat contact points on joint along oil sump (see arrows) with Drei Bond 1209.

Scheme 154

Installation

Lightly oil running surface of crankshaft.

Fit end cover (1) with support sleeve (2) on crankshaft and push on carefully.

Note. Picture shows (N62TU).

Scheme 155

Insert screws (2) and initially tighten without play.

Insert screws (1) and initially tighten without play.

Tighten down screws (2) from inside outwards.

Tighten down screws (1) from inside outwards.

Tightening torque 11 14 4AZ, see 11 14 CASE COVERS

Assemble engine.

11 14 250 Removing and installing/sealing rear coolant end cover (N63)

Special tools required

1. 11 4 470

See ENGINE - SPECIAL TOOLS (N54, N63) .

Recycling

Catch and dispose of drained coolant in a suitable container.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Remove «flywheel»(ref-349795-S30768805762009121000000)
2. Drain coolant . See «17 00 008 DRAINING AND ADDING COOLANT IN RADIATOR (N62TU, N63)»(ref-349799-S10436053892009121000000) .

Release all screws in area (1).

Tightening torque 11 14 5AZ, see 11 14 CASE COVERS

Remove end cover.

Note. Clean sealing faces with special tool 11 4 470.

Scheme 156

Installation

Replace profile seal (1) .

Scheme 157

Assemble engine.

11 21 500 Replacing crankshaft (N63)

Special tools required

1. 00 2 010
2. 00 9 120
3. 11 4 350
4. 11 6 251
5. 11 6 252
6. 13 5 020

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE - SPECIAL TOOLS (N54, N63) .

See FUEL SYSTEM - SPECIAL TOOLS .

Necessary preliminary tasks

1. Remove «engine»(ref-349795-S06065388982009121000000) .
2. Mount engine on assembly stand .
3. Remove «cylinder head»(ref-349795-S32249519472009121000000) .
4. Remove hub for «vibration damper»(ref-349795-S24291936922009121000000) .
5. Remove lower timing case cover.
6. Remove oil «sump»(ref-349795-S30951694292009121000000) .
7. Remove «oil pump»(ref-349795-S39704877712009121000000) .
8. Remove «pistons»(ref-349795-S25586401512009121000000) .
9. Remove «flywheel»(ref-349795-S30768805762009121000000) .
10. Remove «radial»(ref-349795-S17053796222009121000000) shaft seals .
11. Remove «timing chains»(ref-349795-S24310858372009121000000) .

Installation

Layout of main bearing caps.

All numbers must be read from the cylinder bank (5 to 8) (see arrows).

Scheme 158

Main bearing caps (1 to 5) opposite the output end on the timing chain drive.

Scheme 159

Release oil pump spacer pins (1) with special tool 13 5 020.

Scheme 160

Release main bearing taper screw connection (1).

Release oil pump spacer pins (2).

Scheme 161

Release all thread support bushings (1).

Scheme 162

Release collar bolts (M8) in sequence 10 to 1.

Scheme 163

Release collar bolts (M11) in sequence 10 to 1.

Remove main bearing caps 1 to 5.

Lift out crankshaft and set down safely (secure against turning).

Scheme 164

Release screw for oil nozzle (1).

Tightening torque: 11 11 8AZ, see 11 11 ENGINE BLOCK

Scheme 165

Installation

Check oil nozzle (1) for clear passage with compressed air.

Observe fastening on oil nozzle.

Scheme 166

Installation

Observe fastening in crankcase.

Scheme 167

Replace main crankshaft bearing shells .

Installation

Observe arrangement of main bearing caps.

All numbers must be read from the cylinder bank (5 to 8) (see arrows).

Main bearing caps (1) is opposite the output end on the timing chain drive.

Turn back all thread support bushings hand-tight.

Installation

Coat all bearing points with engine oil.

Scheme 168

Install crankshaft.

Fit bearing caps (1 to 5).

Set down bearing caps positioned from 1 to 5.

Insert all collar bolts (M11) hand-tight.

Secure collar bolts (M11) in sequence (1 to 10).

Installation

For a better overview of the screw connection quality, mark the head of all collar bolts after joining with a line (1) using an oil-proof marker pen.

Check angle tightening.

Scheme 169

Secure collar bolt (1) with special tool 00 9 120.

Tightening torque: 11 11 1AZ, see 11 11 ENGINE BLOCK

Scheme 170

Insert all collar bolts (M8) hand-tight.

Secure collar bolts (M8) in sequence (1 to 10).

Installation

For a better overview of the screw connection quality, mark the head of all collar bolts after joining with a line (1) using an oil-proof marker pen.

Check angle tightening.

Secure collar bolt (1) with special tool 00 9 120.

Scheme 171

Secure all thread support bushings (1) with special tool 11 4 350.

Tightening torque: 11 11 3AZ, see 11 11 ENGINE BLOCK

Scheme 172

Secure main bearing taper screw connection (1).

Tightening torque: 11 11 4AZ, see 11 11 ENGINE BLOCK

Secure oil pump spacer pins (2).

Tightening torque: 11 11 5AZ, see 11 11 ENGINE BLOCK

Check crankshaft coefficient of friction .

Determine crankshaft breakaway torque with special tool 00 2 010.

Rotate crankshaft at central bolt with special tool 00 2 010.

If the breakaway torque is too high, it will be necessary to correct the bearing clearance . See CRANKSHAFT WITH BEARING .

Scheme 173

Secure special tool 11 6 252 with magnetic foot on crankcase.

Slide crankshaft in direction of arrow forwards as far as it will go.

Set special tool 11 6 251 to zero.

Slide crankshaft (1) in direction of arrow towards rear and determine value.

Check axial play .

Scheme 174

Assemble engine.

11 21 531 Replacing all main crankshaft bearing shells (N63)

Special tools required

1. 00 2 590
2. 00 9 120
3. 11 6 251
4. 11 6 252

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove «crankshaft»(ref-349795-S25120037512009121000000)

Note. Main bearing caps 1 to 5 are marked with punched numbers.

Observe crankshaft construction stage

S: Series

B: Repair stage 1

C: Repair stage 2

The letters denote the bearing shell classification for the relevant bearing position from 1 to 5 (main bearing cap).

The first letter on the left applies to the first bearing position at the front on the timing chain drive.

Color coding on crankshaft 1 to 5

Y= yellow

G= green

V= violet

Scheme 175

The letters denote the bearing shell classification for the relevant bearing position from 1 to 5 in the crankcase and is located on the transmission side in the Vee. The first letter on the left applies to the first bearing position at the front on the timing chain drive.

Color coding in crankcase 1 to 5.

Y= yellow

G= green

V= violet

Scheme 176

Installation

Install main bearing shells (1) with lubrication groove in crankcase.

Install main bearing shells (2) without lubrication groove in the main bearing caps.

The letters denote the bearing shell classification for the relevant bearing position from 1 to 5 (main bearing cap).

The first letter on the left applies to the first bearing position at the front on the timing chain drive.

Color assignment on crankshaft 1 to 5

Scheme 177

BEARING SHELL CLASSIFICATION LETTER WITH CODE

TOLERANCE CLASSES AND BEARING SHELL COVERS COLOR CODE REFERENCE CHART

Installation note

Install main bearing shells (1) with lubrication groove in crankcase.

Install main bearing shells (2) without lubrication groove in the main bearing caps.

Scheme 178

Note. Main bearing cap number 3 can be identified by the surfaces (1) for the thrust washers of the thrust bearing.

Scheme 179

Turn back thread support bushing into main bearing cap.

Scheme 180

Checking main bearing clearance

To check crankshaft bearing clearance, use the existing main bearing screws.

Scheme 181

Do not twist crankshaft.

Place special tool 00 2 590 (Plastigage model PG 1) on oil-free crankshaft (see arrow).

Tighten down all collar bolts (M11) of main bearing caps in sequence 1 to 5 to jointing torque.

Tightening torque 11 11 1AZ, see 11 11 ENGINE BLOCK

Tighten down all collar bolts (M11) of main bearing caps with special tool 00 9 120 to angle of rotation.

Remove main bearing cap.

Read off main bearing play at width of flattened plastic thread with assistance of measurement scale.

Main bearing play .

1. Remove plastic thread
2. Apply a coat of oil to new bearing shells and crankshaft

Scheme 182

Note. Always replace bolts in main bearing caps with new bolts. Do not wash off bolt coating.

Install crankshaft .

Carefully strike back and front of crankshaft with a plastic hammer to center thrust bearing (do not damage crankshaft).

Secure special tool 11 6 252 with magnetic foot on crankcase.

Position special tool 11 6 251.

Tightening specifications for main bearing

Check side clearance ( axial play ).

Check guide bearing shell, crankshaft and crankcase if necessary.

Assemble engine.

11 22 000 Removing and installing/replacing flywheel (N63)

Special tools required

1. 11 9 260

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove automatic transmission
2. Remove manual transmission
3. Remove clutch

Locate flywheel (1) with special tool 11 9 260.

Scheme 183

Release flywheel screws in area (1).

Remove flywheel (2).

Installation

Clean threads on flywheel screws in crankshaft.

Flywheel (2) is secured with an alignment pin.

Fit flywheel (2).

Fit new flywheel screws .

Tightening torque 11 22 1AZ, see 11 22 FLYWHEEL

Scheme 184

11 22 510 Removing and installing/replacing flywheel (transmission removed - N63)

Special tools required

1. 11 9 260

See ENGINE - SPECIAL TOOLS (N54, N63) .

Locate flywheel (1) with special tool 11 9 260.

Release flywheel screws in area (1).

Remove flywheel (2).

Installation

Clean threads on flywheel screws in crankshaft.

Flywheel (2) is secured with an alignment pin.

Fit flywheel (2).

Fit new flywheel screws .

Tightening torque 11 22 1AZ, see 11 22 FLYWHEEL

11 22 513 Replacing roller bearing for dual-mass flywheel (N63)

Note. FLYWHEEL removed!

Using hydraulic press (1) and special tool 21 2 051, press roller bearing out of dual-mass flywheel downwards on engine side.

Scheme 185

Push roller bearing (2) onto special tool 21 2 052.

Using hydraulic press (1), press roller bearing into dual-mass flywheel as far as it will go on clutch side.

Scheme 186

11 24 571 Replacing all connecting rod bearings (N63)

Special tools required

1. 00 2 590
2. 00 9 120

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

Necessary preliminary tasks

1. Remove all «pistons»(ref-349795-S25586401512009121000000) .

Install new connecting rod bearing shells.

Install one blue bearing shell (1) and one red bearing shell (2) in each conrod.

Install pistons .

Scheme 187

Installation

The bearing shells on the conrod are coded.

Conrod bearing cap (1): the red bearing shell is fitted and the fastening notches are on the left and right sides of the bearing shell (see arrows).

Conrod (2): the blue bearing shell is fitted and the fastening notches are one side of the bearing shell (see arrows).

Scheme 188

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.

Scheme 189

Use conrod bolts to check conrod bearing clearance.

Conrod bolts with special tool 00 9 120.

Tightening torque 11 24 1AZ, see 11 24 CONNECTING RODS AND BEARINGS

Scheme 190

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

Conrod bearing clearance .

1. Remove plastic thread.
2. Lubricate crankshaft and bearing shells.
3. Install new conrod bolts.

Scheme 191

Secure conrod bolts with special tool 00 9 120.

Tightening torque 11 24 1AZ, see 11 24 CONNECTING RODS AND BEARINGS

Assemble engine.

11 25 530 Removing and installing/replacing all pistons (N63) up to 3/2011

Special tools required

1. 00 9 120
2. 11 5 440
3. 11 7 280
4. 11 8 151
5. 11 8 152

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove «engine»(ref-349795-S06065388982009121000000)
2. Mount engine on assembly stand .
3. Remove both left «cylinder head»(ref-349795-S14364938732009121000000) and right «cylinder head»(ref-349795-S30557625472009121000000) .
4. Remove oil «sump»(ref-349795-S30951694292009121000000) .
5. Remove «oil pump»(ref-349795-S39704877712009121000000) .

Unscrew conrod bearing cover.

Note. Connecting rods and connecting rod bearing caps are denoted with the same pairing letters.

The stamped dates are always arranged in opposite directions.

Set down conrod bearing caps in order.

Scheme 192

Note. To install and remove the conrods, it is essential for the crankshaft to be exactly in alignment with the cylinder bore (see dashed line). Position crankshaft at central bolt. Insert special tool 11 8 152 in conrod. Screw special tool 11 5 440 into conrod with bolt (1). Remove conrod with piston from cylinder head side.

Scheme 193

Scheme 194

If necessary, replace connecting rods.

Note. The conrods can also be replaced individually. The gudgeon pin must be able to be pressed through the liner by hand with little force and must not display any significant play.

Scheme 195

Prior to installation, measure piston installation clearance

Measure piston diameter with micrometer at measuring point A from lower edge of piston and offset by 90° to piston pin axis.

Measuring point A .

Scheme 196

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

Diameter of cylinder bore . See ENGINE - TECHNICAL DATA (N63) .

Piston installation clearance . See ENGINE - TECHNICAL DATA (N63) .

Total permissible wear tolerance . See ENGINE - TECHNICAL DATA (N63) .

Scheme 197

Note. The pistons and conrods of cylinders 1 to 8 are identical.

Scheme 198

Arrow on piston crown (cyl. 1 to 4) points upwards, bolt connection on conrod points at an angle to right.

Arrow on piston crown (cyl. 5 to 8) points upwards, bolt connection on conrod points at an angle to left.

Note. For purposes of clarity, pistons are shown removed.

The conrods are correctly mounted on the piston when the bolt connections on the conrods are parallel to each other (see arrow).

Scheme 199

Install retaining ring.

Scheme 200

Installation

Piston circlip (1) is correctly installed when the opening points upwards.

See illustration.

It must still be possible for the piston pin to moved easily.

Scheme 201

Insert special tools 11 8 151 and 11 8 152 in conrod.

Install conrod bearing .

Scheme 202

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.

Note. Picture shows S85.

Scheme 203

Keep piston rings compressed with special tool 11 7 280.

Install piston so that arrow points to camshaft drive.

Press in piston only with finger force (do not knock in!).

Scheme 204

Press in piston (1) only with finger force (do not knock in!).

Scheme 205

The direction arrow on the piston crown must point to the camshaft drive (direction of travel towards front).

Scheme 206

Attach crankpin to connecting rod.

Remove special tools 11 5 440 and 11 8 152.

Note. For purposes of clarity, the pairing letters (1) are shown on the removed conrod.

Fit bearing cap so that pairing letters match up.

Scheme 207

Apply light coat of oil to connecting-rod bearing shells.

Fit bearing cap so that pairing letters match up.

Install new conrod bolts.

Scheme 208

Tighten down conrod bolts (1) with special tool 00 9 120.

Tightening torque 11 24 1AZ . 11 24 CONNECTING RODS AND BEARINGS

Assemble engine.

11 25 530 Removing and installing/replacing all pistons (N63) from 3/2011

Special tools required

1. 00 9 120
2. 11 5 440
3. 11 7 280
4. 11 8 151
5. 11 8 152

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove «engine»(ref-349795-S06065388982009121000000)
2. Mount engine on assembly stand .
3. Remove both left «cylinder head»(ref-349795-S14364938732009121000000) and right «cylinder head»(ref-349795-S30557625472009121000000) .
4. Remove oil «sump»(ref-349795-S30951694292009121000000) .
5. Remove «oil pump»(ref-349795-S39704877712009121000000) .

To release the connecting rod bolts (1), the crankshaft (2) must be moved to a suitable position. Release connecting rod bolts (1).

Scheme 209

Screw the special tool 2 249 164 into the connecting rod.

Scheme 210

Note. For installation and dismantling of the connecting rods, it is essential for the crankshaft to be exactly in alignment with the cylinder bore.

Position crankshaft at central bolt. Press out the connecting rod and piston with special tool 2 249 164 towards the cylinder head side.

Lift out circlip and press out piston pin.

If necessary, replace connecting rods.

Note. The connecting rod can also be replaced individually. The gudgeon pin must be able to be pressed through the bush by hand with little force and must not display any significant play.

Prior to installation, measure piston installation clearance: Measure piston diameter with micrometre at measuring point A from lower edge of piston and offset at 90° to the axis of the gudgeon pin. See PISTON WITH RINGS AND PIN .

Adjust micrometre to cylinder bore of engine block. Set internal measuring device on micrometre to zero. Measure bottom, center and top of cylinder bore in direction of travel and direction of rotation. See ENGINE BLOCK and PISTON WITH RINGS AND PIN .

Installation note: Piston circlip (1) is correctly installed when the opening points upwards.

It must still be possible for the gudgeon pin to be moved easily.

Insert the special tools 2 249 164 into the connecting rod. Install connecting rod bearing.

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 gudgeon pin boss.

Keep piston rings compressed with special tool 11 7 280. Install piston so that arrow points to camshaft drive.

Press in piston only with finger force (do not knock in!).

The direction arrow on the piston crown must point to the camshaft drive (direction of travel towards front).

Connect the crankshaft journal and connecting rod. Remove the special tools 2 249 164.

Scheme 211

Note. For purposes of clarity, the pairing letters (1) are shown on the removed connecting rod.

Apply light coat of oil to connecting rod bearing shells. Fit the bearing cap so that the pairing letters (3) match up. Install the connecting rod bolts (1).

Secure connecting rod bolts (1) with special tool 00 9 120. Tightening torque 11 24 1 AZ.

11 28 010 Replacing alternator drive belt (N63)

Special tools required

1. 11 3 340

See ENGINE - SPECIAL TOOLS (N54, N63) .

Installation

If the drive belt is to be reused, mark direction of travel and reinstall drive belt in same direction of rotation.

Necessary preliminary tasks

1. Remove fan cowl . See «17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (N63)»(ref-349799-S38954538392009121000000) .
2. Release expansion tank for intercooler from mounting and press forwards. See «ENGINE RADIATOR»(ref-349799-S04571686442009121000000) .

Coolant hoses do not need to be released!

Slowly and carefully pretension belt tensioner (1) in direction of arrow up to stop.

Secure special tool 11 3 340 in special tool bore (2).

Belt tensioner in assembly position.

Remove drive belt.

Note. On vehicles which do not have a power steering pump, an idler pulley (3) is fitted in place of the power steering pump.

Scheme 212

Put on the drive belt.

Remove special tool 11 3 340 in special tool bore (2).

Slowly relieve tension on belt tensioner (1).

Installation

Make sure drive belt is in correct installation position.

Scheme 213

Assemble engine.

11 28 020 Replacing tensioning device for alternator drive belt (N63)

Special tools required

1. 11 0 390

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove alternator «drive belt»(ref-349795-S09433897892009121000000)

If necessary, remove special tool 11 0 390.

Release screw (1).

Tightening torque 11 28 1AZ. 11 28 V-RIBBED BELT WITH TENSION AND DEFLECTION ELEMENT

Remove belt tensioner with idler pulley (2).

11 28 050 Replacing A/C compressor drive belt with belt tensioner (N63)

Installation

If the drive belt is to be reused, mark direction of travel and reinstall drive belt in same direction of rotation.

Necessary preliminary tasks

1. Remove alternator «drive belt»(ref-349795-S09433897892009121000000)

Note. Observe direction of engine rotation.

Crank engine at central bolt until marking (see arrow) is reached on vibration damper.

Release screws (1).

Tightening torque 11 28 2AZ, see 11 28 V-RIBBED BELT WITH TENSION AND DEFLECTION ELEMENT

Scheme 214

Note. Observe direction of engine rotation.

Crank engine at central bolt until marking (see arrow) is reached on vibration damper.

Remove elasto-belt.

Scheme 215

Assemble engine.

11 31 032 Removing and installing/replacing left inlet camshaft (N63)

Special tools required

1. 11 4 480

See ENGINE - SPECIAL TOOLS (N54, N63) .

(cylinder bank 5 to 8)

Necessary preliminary tasks

1. Remove left «cylinder head cover»(ref-349795-S16865618692009121000000) .
2. Check «timing»(ref-349795-S32155175162009121000000) .
3. Remove left inlet «adjustment unit»(ref-349795-S18155197382009121000000) .

Rotate left inlet camshaft with a fork wrench (1) into a suitable position.

Scheme 216

Release bolts of camshaft bearings in sequence (10 to 1) in 1/2 turns.

Set down all bearing caps in a tidy and orderly fashion on special tool 11 4 480.

Inlet camshaft

Scheme 217

Note. Rocker arms (1) are freely accessible after inlet camshaft has been removed. Do "not" remove rocker arm (1) on inlet side.

Scheme 218

If necessary, replace plain compression rings (1).

Press compression ring (1) on one side into groove, pull up on other side and remove catch.

Carefully pull compression ring (1) apart and remove towards front.

Ends of compression rings (1) point upwards.

Make sure compression rings (1) are engaged at ends.

Scheme 219

Note. Inlet camshaft of cylinder bank 5 to 8 is marked with "E 5-8".

Scheme 220

Align all rocker arms (1) straight.

Coat all bearing points with engine oil.

Insert inlet camshaft.

Scheme 221

Insert inlet camshaft (1) so that cams point to side at cylinder 5 as shown in picture.

Scheme 222

Scheme 223

All bearing caps are marked

L = cylinders 1-4

R= cylinders 5-8

E = inlet side

A = exhaust side

1 = designation from 1 to 5

Insert all bolts.

Tighten down bolts in sequence (1 to 10) in 1/2 turns.

Tightening torque: 11 31 6AZ. 11 31 CAMSHAFT

Tightening torque: 11 31 7AZ, see 11 31 CAMSHAFT

Install inlet adjustment unit .

Adjust valve timing. See left side and camshaft timing on right side .

Assemble engine.

11 31 034 Removing and installing/replacing right inlet camshaft (N63)

Special tools required

1. 11 4 480

See ENGINE - SPECIAL TOOLS (N54, N63) .

(cylinder bank 1 to 4)

Necessary preliminary tasks

1. Remove right «cylinder head cover»(ref-349795-S30084915142009121000000) .
2. Check «timing»(ref-349795-S32155175162009121000000) .
3. Remove right inlet «adjustment unit»(ref-349795-S17868430142009121000000) .

Rotate right inlet camshaft (2) at dihedron with a fork wrench (1) into a suitable position.

Note. Illustration shows cyl. 5 to 8.

Release bolts of camshaft bearings in sequence (10 to 1) in 1/2 turns.

Set down all bearing caps in a tidy and orderly fashion on special tool 11 4 480.

Inlet camshaft

Scheme 224

Note. Rocker arms (1) are freely accessible after inlet camshaft has been removed. Do "not" remove rocker arm (1) on inlet side.

If necessary, replace plain compression rings (1).

Press compression ring (1) on one side into groove, pull up on other side and remove catch.

Carefully pull compression ring (1) apart and remove towards front.

Ends of compression rings (1) point upwards.

Make sure compression rings (1) are engaged at ends.

Note. Inlet camshaft of cylinder bank 5 to 8 is marked with "E 5-8".

Align all rocker arms (1) straight.

Coat all bearing points with engine oil.

Scheme 225

Insert inlet camshaft.

Insert inlet camshaft (1) so that cams point to side at cylinder 1 as shown in picture.

Scheme 226

All bearing caps are marked with letters and numbers

Scheme 227

L = cylinder bank 1-4

R= cylinder bank 5-8

E = inlet side

A = exhaust side

1 = designation, bearing point, from 1 to 5

Insert all bolts.

Tighten down bolts in sequence (1 to 10) in 1/2 turns.

Tightening torque: 11 31 6AZ, see 11 31 CAMSHAFT

Tightening torque: 11 31 7AZ, see 11 31 CAMSHAFT

Install inlet adjustment unit .

Adjust valve timing . See left side and right side

Assemble engine.

11 31 036 Removing and installing/replacing left exhaust camshaft (N63)

Special tools required

1. 11 4 480

See ENGINE - SPECIAL TOOLS (N54, N63) .

(cylinder bank 5 to 8)

Necessary preliminary tasks

1. Remove left «cylinder head cover»(ref-349795-S16865618692009121000000) .
2. Check «timing»(ref-349795-S32155175162009121000000) .
3. Remove left inlet «adjustment unit»(ref-349795-S18155197382009121000000) .

Rotate exhaust camshaft (2) at dihedron with a fork wrench into a suitable position.

Release bolts of camshaft bearings in sequence (10 to 1) in 1/2 turns.

Set down all bearing caps in a tidy and orderly fashion on special tool 11 4 480.

Remove roller tappet from bearing cap (2 and 3) of high-pressure pump and set down on special tool 11 4 480.

Remove left exhaust camshaft and set down on special tool 11 4 480.

Scheme 228

Note. Rocker arms (1) are freely accessible after exhaust camshaft has been removed. Do "not" remove rocker arms (1) on exhaust side.

If necessary, replace plain compression rings (1).

Press compression ring (1) on one side into groove, pull up on other side and remove catch.

Carefully pull compression ring (1) apart and remove towards front.

Ends of compression rings (1) point upwards.

Make sure compression rings (1) are engaged at ends.

Note. Exhaust camshaft of cylinder bank 5 to 8 is marked with "A 5-8".

Align all rocker arms (1) straight.

Coat all bearing points with engine oil.

Install exhaust camshaft (1).

Insert exhaust camshaft (1) so that cams point to side at cylinder 5 as shown in picture.

Scheme 229

All bearing caps are marked

L = cylinders 1-4

R= cylinders 5-8

E = intake side.

A = exhaust side.

1 = designation from 1 to 5

Insert all bolts.

Tighten down bolts in sequence (1 to 10) in 1/2 turns.

Tightening torque: 11 31 6AZ, see 11 31 CAMSHAFT

Tightening torque: 11 31 7AZ. 11 31 CAMSHAFT

Insert tappets for high-pressure pump.

Install inlet adjustment unit .

Adjust valve timing . See left side and camshaft timing on right side

Assemble engine.

11 31 038 Removing and installing/replacing right exhaust camshaft (N63)

Special tools required

1. 11 4 480

See ENGINE - SPECIAL TOOLS (N54, N63) .

Cylinders 1-4

Necessary preliminary tasks

1. Remove right high-pressure pump . See «13 51 065 REMOVING AND INSTALLING/REPLACING LEFT HIGH-PRESSURE FUEL PUMP (N63)»(ref-349797-S00637477832009121000000) or «13 51 070 REMOVING AND INSTALLING/REPLACING RIGHT HIGH-PRESSURE FUEL PUMP (N63)»(ref-349797-S05860536602009121000000) .
2. Remove right «cylinder head cover»(ref-349795-S30084915142009121000000)
3. Remove right exhaust «adjustment unit»(ref-349795-S18155197382009121000000)

Rotate exhaust camshaft (2) at dihedron with a fork wrench into a suitable position.

Note. Inlet camshaft of cylinder bank 5-8 is marked with "E 5-8".

Release bolts of camshaft bearings in sequence (10 to 1) in 1/2 turns.

Set all bearing caps down in special tool 11 4 480 in a tidy and orderly fashion.

Remove roller tappet from bearing cap (2 and 3) of high-pressure pump and set down in special tool 11 4 480.

Remove left exhaust camshaft and set down in special tool 11 4 480.

Scheme 230

Align all rocker arms (1) straight.

If necessary, replace plain compression rings (1).

Press compression ring (1) on one side into groove, pull up on other side and remove catch.

Carefully pull compression ring (1) apart and remove towards front.

Ends of compression rings (1) point upwards.

Make sure compression rings (1) are engaged at ends.

Coat all bearing points with engine oil.

Scheme 231

Install exhaust camshaft (1).

Turn exhaust camshaft (1) until cams point to side at cylinder no. 1 as shown in graphic.

Scheme 232

All bearing caps are marked with letters and numbers

L = cylinder bank 1-4

R= cylinder bank 5-8

E = inlet side

A = exhaust side

1 = Marking, bearing point, from 1 to 5

Insert all bolts.

Tighten down bolts in sequence (1 to 10) in 1/2 turns.

Tightening torque 11 31 6AZ, see 11 31 CAMSHAFT

Tightening torque 11 31 7AZ, see 11 31 CAMSHAFT

Install right inlet and exhaust adjustment units .

Adjust valve timing . See left side and right side .

Assemble engine.

11 31 052 Replacing both timing chains (N63)

Special tools required

1. 00 2 300
2. 11 2 001
3. 11 2 002
4. 11 2 003
5. 11 2 007

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove lower «timing case cover»(ref-349795-S18878592192009121000000)
2. To facilitate removal and installation of timing chains, turn engine over with special tool 00 2 300.

Timing drive, cylinders 1 to 4 .

Remove guide rail (5) from bearing bolt.

Remove timing chain (3) with tensioning rail (4) from bearing bolt.

Timing drive, cylinders 5 to 8 .

Remove guide rail (1) from bearing bolt.

Remove timing chain (2) with tensioning rail (6) from bearing bolt.

Scheme 233

Timing drive, cylinders 1 to 4 .

Release bearing bolts (2) with a suitable tool.

Tightening torque: 11 31 1AZ. 11 31 CAMSHAFT

Timing drive, cylinders 5 to 8 .

Release bearing bolts (1).

Scheme 234

Attach special tools 11 2 001 and 11 2 002 to crankshaft.

Insert special tool 11 2 007 and remove sprocket wheel with special tool 11 2 003.

Installation

Check sprocket wheels for wear, replace if necessary.

Heat sprocket wheel to 60°C .

Scheme 235

Installation

Make sure Woodruff key (1) is installed in correct position in crankshaft (2).

Scheme 236

Installation

Maintain tension of timing chains when installing timing case cover.

Observe sparking protection on timing case cover.

Make sure timing chain (1) is correctly installed when placing it in guide rail (3).

Assemble engine.

11 31 070 Checking camshaft timing on left side (N63)

Special tools required

1. 00 9 250
2. 11 8 570
3. 11 9 190
4. 11 9 893
5. 11 9 900

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE - SPECIAL TOOLS (N54, N63) .

Cylinders 5 - 8

Necessary preliminary tasks

1. Remove left «cylinder head cover»(ref-349795-S16865618692009121000000)
2. Remove fan cowl with electric fan. See «17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (N63)»(ref-349799-S38954538392009121000000) .
3. Remove «belt pulley»(ref-349795-S32566104342009121000000) for A/C system. See.
4. Remove left «chain tensioner»(ref-349795-S00246127482009121000000)

Mount special tool 11 9 900 at position of chain tensioner.

Preload hexagon socket screw with special tool 00 9 25 to 0.6 Nm .

Note. Graphic corresponds to cylinders 1-4.

Scheme 237

Note. Marking (MP = Mounting Position) is important for installing special tool 11 8 570.

MP = 150° before cylinder no. 1 firing TDC position .

Scheme 238

Position special tool 11 8 570 with dihedron on vibration damper in such a way that it can be secured with bolt (1) at the MP marking.

Note. Setting groove on crankcase, see arrow.

Scheme 239

Crank engine at central bolt.

Secure vibration damper with special tools 11 8 570 and 11 9 190 at 150° before cylinder no. 1 firing TDC position .

Scheme 240

With cylinder no. 1 at 150° before firing TDC position, cams on exhaust camshaft (A) at cylinder no. 5 point at an angle to the left.

Cams on inlet camshaft (E) point at an angle downwards.

Note. For purposes of clarity, the graphic shows the inlet and exhaust adjustment units removed.

Scheme 241

Checking locking of inlet and exhaust adjustment units in initial position

Gripping hexagon head (2) of camshafts with a fork wrench (1), carefully try to rotate camshafts against direction of rotation.

The inlet and exhaust adjustment units are locked in the initial position when the camshafts are non-positively connected to the adjustment units.

Fit special tool 11 9 893 on exhaust camshaft and check timing adjustment.

Note. Timing is correctly adjusted when special tool 11 9 893 rests without a gap on cylinder head.

Scheme 242

Fit special tool 11 9 893 on inlet camshaft and check timing adjustment.

Note. Timing is correctly adjusted when special tool 11 9 893 rests without a gap on cylinder head. If necessary, adjust camshaft timing on left side.

Scheme 243

Remove all special tools.

Assemble engine.

11 31 071 Checking camshaft timing on right side (N63)

Special tools required

1. 00 9 250
2. 11 8 570
3. 11 9 190
4. 11 9 893
5. 11 9 900

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove right «cylinder head cover»(ref-349795-S30084915142009121000000) .
2. Remove fan cowl with electric fan. See «17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (N63)»(ref-349799-S38954538392009121000000) .
3. Remove «belt pulley»(ref-349795-S32566104342009121000000) for A/C system.
4. Remove right «chain tensioner»(ref-349795-S09403327562009121000000) .

Mount special tool 11 9 900 at position of chain tensioner.

Preload hexagon socket screw with special tool 00 9 250 to 0.6 Nm .

Note. Marking (MP = Mounting Position) is important for installing special tool 11 8 570.

MP = 150° before cylinder no. 1 firing TDC position .

Position special tool 11 8 570 with dihedron on vibration damper in such a way that it can be secured with bolt (1) at the MP marking.

Note. Setting groove on crankcase, see arrow.

Crank engine at central bolt.

Secure vibration damper with special tools 11 8 570 and 11 9 190x at 150° before cylinder no. 1 firing TDC position .

With cylinder no. 1 at 150° before firing TDC position, cams on exhaust camshaft (A) at cylinder no. 1 point at an angle upwards.

Cams on inlet camshaft (E) point at an angle downwards.

Note. For purposes of clarity, the graphic shows the inlet and exhaust adjustment units removed.

Scheme 244

In order to avoid incorrect timing adjustment, it is essential to check the locking of the adjustment unit and if necessary perform locking by rotating the camshafts.

Checking locking of inlet and exhaust adjustment units in initial position

Gripping hexagon head (2) of camshafts with a fork wrench (1), carefully try to rotate camshafts against direction of rotation.

The inlet and exhaust adjustment units are locked in the initial position when the camshafts are non-positively connected to the adjustment units.

Note. Graphic corresponds to cylinders 5-8.

Fit special tool 11 9 893 on exhaust camshaft and check timing adjustment.

Note. Timing is correctly adjusted when special tool 11 9 893 rests without a gap on cylinder head.

Scheme 245

Fit special tool 11 9 893 on inlet camshaft and check timing adjustment.

Note. Timing is correctly adjusted when special tool 11 9 893 rests without a gap on cylinder head. If necessary, adjust camshaft timing on right side.

Scheme 246

Remove all special tools.

Assemble engine.

11 31 094 Removing hydraulic chain tensioner for timing chains on left side (N63)

Special tools required

1. 11 9 900

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove «timing case cover»(ref-349795-S26108192622009121000000) at top left

Crank engine back at central bolt (1) against direction of engine rotation by approx. 90°.

Scheme 247

Piston (1) of chain tensioner must be pressed in against oil pressure in housing (see arrow).

Scheme 248

If the chain tensioner piston is retracted over its full length, a 3.5 mm drill bit or a suitable lock pin must be positioned.

Scheme 249

Release bolts (1).

Tightening torque 11 31 5AZ, see 11 31 CAMSHAFT

Remove chain tensioner (2).

Scheme 250

Chain tensioner arrangement

1. Piston
2. Expansion element
3. Spring
4. Housing

Scheme 251

Installation

Replace all gaskets and sealing rings .

Assemble engine.

11 31 095 Removing hydraulic chain tensioner for timing chains on right side (N63)

Special tools required

1. 11 9 900

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove «timing case cover»(ref-349795-S01204482652009121000000) at top right

Crank engine back at central bolt (1) against direction of engine rotation by approx. 180°.

Scheme 252

Piston (1) of chain tensioner must be pressed in against oil pressure in housing (see arrow).

If the chain tensioner piston is retracted over its full length, a 3.5 mm drill bit or a suitable lock pin must be positioned.

Release bolts (1).

Tightening torque 11 31 5AZ, see 11 31 CAMSHAFT

Remove chain tensioner (2).

Chain tensioner arrangement

1. Piston
2. Expansion element
3. Spring
4. Housing

Installation

Replace all gaskets and sealing rings .

Assemble engine.

11 31 573 Adjusting camshaft timing on left side (N63)

Special tools required

1. 00 9 120
2. 11 8 570
3. 11 9 190
4. 11 9 890
5. 11 9 891
6. 11 9 892
7. 11 9 893
8. 11 9 894

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE - SPECIAL TOOLS (N54, N63) .

(cylinder bank 5 to 8)

Necessary preliminary tasks

1. Remove left «timing case cover»(ref-349795-S26108192622009121000000)
2. Check camshaft timing on left side

Get special tool kit 11 9 890 ready for securing camshafts.

Note. Special tool 11 9 891 Knurled screw. Special tool 11 9 892 Press-down bar. Special tool 11 9 893 Gap gauge for inlet and exhaust camshafts. Special tool 11 9 894 Spacer.

Scheme 253

Release central bolts (1 and 2) of inlet and exhaust adjustment units.

Installation

Replace central bolts after releasing.

Scheme 254

Installation

Coat contact face of new central bolt (1) with copper paste.

Scheme 255

Position special tool 11 9 893 on inlet and exhaust camshafts.

Special tool 11 9 893 must rest without a gap on cylinder head; if necessary, adjust camshaft at hexagon heads.

Screw special tool 11 9 894 into cylinder head.

Scheme 256

Position special tool 11 9 892 on special tool 11 9 893.

Both special tools 11 9 893 are secured with special tool 11 9 891.

Note. Tighten down special tool 11 9 891 by hand.

Scheme 257

Secure central bolt (1) of right inlet adjustment unit with special tool 00 9 120.

Secure central bolt (2) of right exhaust adjustment unit with special tool 00 9 120.

Tightening torque: 11 36 1AZ, see 11 36 VARIABLE CAMSHAFT CONTROL

Remove special tools 11 9 190 and 11 8 570.

Crank engine at central bolt twice in direction of engine rotation until engine returns to 150° before cylinder no. 1 firing TDC position .

Secure vibration damper with special tool 11 9 190 at 150° before cylinder no. 1 firing TDC position .

Fit special tool 11 9 893 on exhaust camshaft and check timing adjustment.

Note. Timing is correctly adjusted when special tool 11 9 893 rests without a gap on cylinder head.

Fit special tool 11 9 893 on inlet camshaft and check timing adjustment.

Note. Timing is correctly adjusted when special tool 11 9 893 rests without a gap on cylinder head.

Remove all special tools.

Assemble engine.

11 31 574 Adjusting camshaft timing on right side (N63)

Special tools required

1. 00 9 120
2. 11 8 570
3. 11 9 190
4. 11 9 890
5. 11 9 891
6. 11 9 892
7. 11 9 893
8. 11 9 894

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE - SPECIAL TOOLS (N54, N63) .

(cylinder bank 1 to 4)

Necessary preliminary tasks

1. Remove right «timing case cover»(ref-349795-S01204482652009121000000)
2. Check camshaft timing on right side .

Get special tool kit 11 9 890 ready for securing camshafts.

Note. Special tool 11 9 891 Knurled screw. Special tool 11 9 892 Press-down bar. Special tool 11 9 893 Gap gauge for inlet and exhaust camshafts. Special tool 11 9 894 Spacer.

Scheme 258

Installation

Replace central bolts after releasing.

Installation

Coat contact face of new central bolt (1) with copper paste.

Position special tool 11 9 893 on inlet and exhaust camshafts.

Special tool 11 9 893 must rest without a gap on cylinder head; if necessary, adjust camshaft at hexagon heads.

Screw special tool 11 9 894 into cylinder head.

Scheme 259

Position special tool 11 9 892 on special tool 11 9 893.

Both special tools 11 9 893 are secured with special tool 11 9 891.

Note. Tighten down special tool 11 9 891 by hand.

Scheme 260

Secure central bolt (1) of right inlet adjustment unit with special tool 00 9 120.

Secure central bolt (2) of right exhaust adjustment unit with special tool 00 9 120.

Tightening torque: 11 36 1AZ, see 11 36 VARIABLE CAMSHAFT CONTROL

Remove special tools 11 9 190 and 11 8 570.

Crank engine at central bolt twice in direction of engine rotation until engine returns to 150° before cylinder no. 1 firing TDC position .

Secure vibration damper with special tool 11 9 190 at 150° before cylinder no. 1 firing TDC position .

Fit special tool 11 9 893 on exhaust camshaft and check timing adjustment.

Note. Timing is correctly adjusted when special tool 11 9 893 rests without a gap on cylinder head.

Fit special tool 11 9 893 on inlet camshaft and check timing adjustment.

Note. Timing is correctly adjusted when special tool 11 9 893 rests without a gap on cylinder head.

Remove all special tools.

Assemble engine.

11 33 052 Removing and installing/replacing all rocker arms on left side (N63)

Special tools required

1. 11 4 480

See ENGINE - SPECIAL TOOLS (N54, N63) .

(cylinder bank 5 to 8)

Necessary preliminary tasks

1. Remove left «inlet camshaft»(ref-349795-S38697867312009121000000) .
2. Remove left «exhaust camshaft»(ref-349795-S41122958542009121000000) .

Remove rocker arm (1) and set down in neat order in special tool 11 4 480.

Install rocker arm (1).

Align all rocker arms (1) straight.

Assemble engine.

11 33 054 Removing and installing/replacing rocker arms on right side (N63)

Special tools required

1. 11 4 480

See ENGINE - SPECIAL TOOLS (N54, N63) .

(cylinder bank 1 to 4)

Necessary preliminary tasks

1. Remove inlet and exhaust «adjustment unit»(ref-349795-S17868430142009121000000) on right side.
2. Remove right «inlet camshaft»(ref-349795-S11901017632009121000000) .
3. Remove right «exhaust camshaft»(ref-349795-S12703293252009121000000) .

Remove rocker arm (1) and set down in neat order in special tool 11 4 480.

Install rocker arm (1).

Align all rocker arms (1) straight.

Assemble engine.

11 34 552 Removing and installing/replacing all valves (N63)

Special tools required

1. 11 4 480
2. 11 8 840
3. 11 9 006
4. 11 9 008

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove «left cylinder head»(ref-349795-S14364938732009121000000) .
2. Remove «right cylinder head»(ref-349795-S30557625472009121000000) .
3. Remove «camshafts»(ref-349795-S27972591952009121000000) .

Mount cylinder head (1) on special tool 11 9 000.

Scheme 261

Prepare special tool 11 9 008 on special tool 11 9 006.

Scheme 262

Position special tool 11 9 006 with silicone cushion on cylinder head.

Slide locks (1) in direction of arrow and pretension with eccentric shaft.

Scheme 263

Press down valve spring with special tool 11 8 840.

Scheme 264

Remove valve cotters (1) with a magnet.

Place valve springs and valve cotters on special tool 11 4 480 in a tidy and orderly fashion.

Scheme 265

Scheme 266

Arrangement

1. Valve
2. Valve stem seal with spring plate, bottom
3. Valve spring
4. Top plate spring
5. Valve cotters

Scheme 267

Release special tool 11 9 006 from cylinder head.

Remove all valves and place on special tool 11 4 480 in a tidy and orderly fashion.

Scheme 268

Assemble engine.

11 34 560 Replacing all valve stem seals (N63)

Special tools required

1. 11 1 380
2. 11 6 370
3. 11 6 380

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove all «valve springs»(ref-349795-S15057377472009121000000) .

Press special tool 11 6 370 onto valve stem seal.

Withdraw valve stem seal by turning and simultaneously unscrewing special tool 11 6 370.

Scheme 269

Installation

Lubricate valve stem with oil and insert valve.

Installation sleeve 11 1 380 is included in the delivery specification for the valve stem seals.

Fit special tool 11 1 380.

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

Scheme 270

Note. For use on the N63 engine, the special tool 11 6 380 must be remachined according to the sketch with a 6.2 mm drill bit dia. to a depth of A = approx. 45 mm. This modification has already been taken into account for reordering.

Scheme 271

Press valve stem seal firmly home by hand with special tool 11 6 380.

Scheme 272

Assemble engine.

11 34 715 Replacing all valve springs (N63)

Special tools required

1. 11 4 480
2. 11 8 840
3. 11 9 000
4. 11 9 006
5. 11 9 008

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Remove «left cylinder head»(ref-349795-S14364938732009121000000) .
2. Remove «right cylinder head»(ref-349795-S30557625472009121000000) .
3. Remove «camshafts»(ref-349795-S27972591952009121000000) .

Mount cylinder head (1) on special tool 11 9 000.

Prepare special tool 11 9 008 on special tool 11 9 006.

Position special tool 11 9 006 with silicone cushion on cylinder head.

Slide locks (1) in direction of arrow and pretension with eccentric shaft.

Press down valve spring with special tool 11 8 840.

Remove valve cotters (1) with a magnet.

Place valve springs and valve cotters on special tool 11 4 480 in a tidy and orderly fashion.

Arrangement

1. Valve
2. Valve stem seal with spring plate, bottom
3. Valve spring
4. Top plate spring
5. Valve cotters

Assemble engine.

11 36 715 Removing and installing/replacing both solenoid valves on left side (N63)

Solenoid valves, cylinders 5-8

Necessary preliminary tasks

1. Read out fault memory in DME control unit
2. Switch off ignition
3. Unlock hose on tank venting valve and disconnect
4. Remove left intercooler . See «17 51 001 REMOVING AND INSTALLING/REPLACING LEFT INTERCOOLER (N63)»(ref-349799-S11197747742009121000000) or «17 51 001 REMOVING AND INSTALLING/REPLACING RIGHT INTERCOOLER (N63)»(ref-349799-S04939739542009121000000) .
5. Carefully press pipe to one side

Note. Solenoid valve (2) controls the inlet adjustment unit. Solenoid valve (4) controls the exhaust adjustment unit.

Unlock plug connections of solenoid valves (2 and 4) and disconnect.

Installation

Plug connections must snap audibly into place!

Scheme 273

Unfasten screws (1 and 3).

Tightening torque 11 36 3AZ, see 11 36 VARIABLE CAMSHAFT CONTROL

Pull out solenoid valves (2 and 4).

Installation

Replace O-rings (1 and 2) on solenoid valve .

Installation

To install solenoid valves, coat both O-rings with engine oil.

If the solenoid valve is to be reused, the filter strainer (see arrow) must be cleaned.

Scheme 274

If a filter element is clogged with dirt, the filter element (filter strainer) may be removed.

Release filter elements (1) at contact edges.

Scheme 275

Bend open welding spots on filter element (1) with a screwdriver (2) in direction of arrow until welding spots are opened.

Scheme 276

Avoid damaging, e.g. notches or scratches, the solenoid valve housing (see arrows).

Scheme 277

Carefully insert solenoid valves (2 and 4) up to stop.

Ensure correct installation position.

Insert screws (1 and 3) and tighten down.

Tightening torque 11 36 3AZ, see 11 36 VARIABLE CAMSHAFT CONTROL

Assemble engine.

Now clear the fault memory.

Check function of DME control unit.

11 36 720 Removing and installing/replacing both solenoid valves on right side (N63)

Solenoid valves, cylinders 1-4

Necessary preliminary tasks

1. Read out fault memory in DME control unit
2. Switch off ignition
3. Remove right intercooler . See «17 51 001 REMOVING AND INSTALLING/REPLACING LEFT INTERCOOLER (N63)»(ref-349799-S11197747742009121000000) or «17 51 001 REMOVING AND INSTALLING/REPLACING RIGHT INTERCOOLER (N63)»(ref-349799-S04939739542009121000000) .
4. Release holder for electropneumatic pressure converter (EPPC) and carefully press to one side

Note. Solenoid valve (4) controls the inlet adjustment unit. Solenoid valve (2) controls the exhaust adjustment unit.

Unlock plug connections of solenoid valves (2 and 4) and disconnect.

Scheme 278

Installation

Plug connections must snap audibly into place!

Unfasten screws (1 and 3).

Tightening torque 11 36 3AZ, see 11 36 VARIABLE CAMSHAFT CONTROL

Pull out solenoid valves (2 and 4).

Installation

Replace O-rings (1 and 2) on solenoid valve .

Installation

To install solenoid valves, coat both O-rings with engine oil.

If the solenoid valve is to be reused, the filter strainer (see arrow) must be cleaned.

Note. If a filter element is clogged with dirt, the filter element (filter strainer) may be removed. Release filter elements (1) at contact edges.

Bend open welding spots on filter element (1) with a screwdriver (2) in direction of arrow until welding spots are opened.

Avoid damaging, e.g. notches or scratches, the solenoid valve housing (see arrows).

Carefully insert solenoid valves (2 and 4) up to stop.

Ensure correct installation position.

Insert screws (1 and 3) and tighten down.

Tightening torque 11 36 3AZ, see 11 36 VARIABLE CAMSHAFT CONTROL

Assemble engine.

Now clear the fault memory.

Check function of DME control unit.

11 40 000 Checking engine oil pressure

Special tools required

1. 11 4 050
2. 13 3 061
3. 13 3 063
4. 13 6 051
5. 13 6 054

See ENGINE - SPECIAL TOOLS (N54, N63) .

See FUEL SYSTEM - SPECIAL TOOLS .

Note. To check the engine oil pressure, remove the oil pressure switch and install and connect the special tool.

Note. A small amount of engine oil emerges when the oil pressure switch is removed.

Have a cleaning cloth ready .

Necessary preliminary tasks

1. Follow BMW diagnosis instruction
2. Remove oil pressure switch . See «12 61 280 REMOVING AND INSTALLING/REPLACING OIL PRESSURE SENSOR (N63)»(ref-349796-S07810847642009121000000) .

Special tool 11 4 050 is fitted with a sealing ring (1).

Scheme 279

Screw special tool 11 4 050 into crankcase to max. 20 Nm.

Secure union nut (1) of special tool 13 3 063 to max. 15 Nm.

Scheme 280

Checking engine oil pressure with DIS Tester

Screw special tool 13 6 054 with sealing ring (1) into special tool 13 6 051 and connect to DIS Tester.

Checking engine oil pressure with pressure gauge

Connect special tool 13 3 063 to special tool 13 3 061 (pressure gauge).

Start engine and check engine oil pressure.

Specified value .

Scheme 281

11 41 000 Removing and installing/replacing oil pump (N63)

Special tools required

1. 00 9 120
2. 11 7 201
3. 11 8 920
4. 11 9 280
5. 51 0 342

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE - SPECIAL TOOLS (N54, N63) .

See BODY EQUIPMENT - SPECIAL TOOLS .

Necessary preliminary tasks

1. Drain «engine oil»(ref-349795-S20762240782009121000000) .
2. Remove «upper oil sump section»(ref-349795-S07846437932009121000000) .

Unscrew nuts (2).

Tightening torque: 11 41 1AZ, see 11 41 OIL PUMP WITH STRAINER AND DRIVE

Remove intake pipe (1).

Installation

Replace O-ring.

Release all nuts (1) with special tool 11 7 201.

Tightening torque 11 41 5AZ . See 11 41 OIL PUMP WITH STRAINER AND DRIVE

Remove oil pump sprocket wheel.

Note. Picture shows engine removed.

Scheme 282

Unscrew nuts (1).

Release screws, remove oil pump (1) with aid of a second person.

Installation

Replace screws.

Tightening torque 11 41 2AZ, see 11 41 OIL PUMP WITH STRAINER AND DRIVE

Scheme 283

Detach oil lines (1) upwards in direction of arrow.

Scheme 284

Installation

Replace sealing rings (1).

Apply light coat of oil to sealing ring (1).

Coat sealing ring (2) with suitable antiseize agent.

Scheme 285

Installation

Replace O-ring (1) for oil feed line.

Scheme 286

Fit oil lines (1) in direction of arrow.

Installation

If the oil pump is replaced, it will be necessary to modify the oil deflector.

Release screws (1).

Tightening torque: 11 41 6AZ, see 11 41 OIL PUMP WITH STRAINER AND DRIVE

Modify oil deflector (2).

Scheme 287

Mount special tool 11 8 920 on special tool 11 9 280.

Scheme 288

Scheme 289

Scheme 290

Installation

Check dihedron on pump shaft (1) for damage.

Scheme 291

Scheme 292

Join and secure nuts (1).

Tightening torque 11 41 2AZ, see 11 41 OIL PUMP WITH STRAINER AND DRIVE

Install oil pump sprocket wheel.

Secure all nuts (1) with special tool 11 7 201.

Tightening torque 11 41 5AZ, see 11 41 OIL PUMP WITH STRAINER AND DRIVE

Adjust oil pump timing chain .

Pretension oil pump adjusting sleeve (1) with a hexagon socket screw key.

Adjustment value 10 mm ±2 .

Scheme 293

Minimally pretension timing chain (1) with special tool 51 0 342.

Read off and make a note of measured value A on special tool 51 0 342.

Scheme 294

Using a screwdriver (1), pretension timing chain to minimal extent in direction of arrow.

Read off and make a note of measured value B on special tool 51 0 342.

Measured value A minus measured value B produces the adjustment value.

Adjustment value 10 mm ±2 .

Scheme 295

Procedure on installed engine

Upper oil sump has been installed.

Position drag pointer (1) of special tool 2 213 485 on oil pump chain.

Scheme 296

Installation note: Attachment point (1) N63 / S63. Attachment point (2) N74.

Scheme 297

Push drag pointer (1) to the left and right until value has been determined. Adjustment value 10 mm +2.

Adjust oil pump timing chain.

Pretension oil pump adjusting sleeve (1) with a hexagon socket wrench. Adjustment value 10 mm +2 .

Note. Graphic without top oil sump

Join and secure screw (2).

Tightening torque 11 41 2AZ, see 11 41 OIL PUMP WITH STRAINER AND DRIVE

Assemble engine.

11 41 150 Removing and installing/replacing roller chain for oil pump drive (N63)

Special tools required

1. 11 7 201
2. 22 13 485

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

See ENGINE AND GEARBOX SUSPENSION - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Drain «engine oil»(ref-349795-S20762240782009121000000) .
2. Remove «flywheel»(ref-349795-S03487057012009121000000) .
3. Remove «bottom of oil sump»(ref-349795-S07846437932009121000000) .

Note. Support bush (2) is included in delivery specification.

If the crankshaft seal (1) is stored for more than six months without the support sleeve (2), its operational reliability will no longer be guaranteed. Crankshaft seal (1) must not be reused in this case! Support bush (2) remains in the crankshaft seal (1) and is used as a slip bush during described installation described below.

Scheme 298

Unscrew nuts (2). Tightening torque: 11 41 1 AZ . Remove intake pipe (1).

Installation note: Replace O-ring.

Release all nuts (1) using special tool 11 7 201. Tightening torque: 11 41 5AZ. . Remove oil pump drive gear.

Note. Graphic shows engine removed

Unscrew nuts (1). Release screws, remove oil pump (1) with aid of a second person.

Installation note: Replace screws. Tightening torque: 11 41 2AZ.

Note. Graphic without top oil sump

Pull off engine oil line (1) upwards in direction of arrow.

Note. Graphic without top oil sump

Installation note: Replace sealing rings (1). Lightly oil sealing ring 1 (1). Coat engine oil pipe (2) with suitable lubricant.

Installation note: Replace O-ring (1) for oil feed line.

Fit engine oil pipe (1) in direction of arrow.

Feed out roller chain (1) via the crankshaft (2).

Scheme 299

Installation note: Mount new roller chain (1). Install oil pump and adjust.

Procedure on installed engine

Upper oil sump has been installed.

Position drag pointer (1) of special tool 2 213 485 on oil pump chain.

Scheme 300

Installation note: Attachment point (1) N63O0 / N63O1/S63O0. Attachment point (2) N74.

Scheme 301

Push drag pointer (1) to the left and right until value has been determined. Adjustment value 10 mm +2 .

Scheme 302

Adjust oil pump timing chain.

Pretension oil pump adjusting sleeve (1) with a hexagon socket wrench. Adjustment value 10 mm +2 .

Note. Graphic without top oil sump

Join and secure screw (2). Tightening torque 11 41 2 AZ

Note. Graphic without top oil sump

Installation note: Check fitting sleeves (1) for damage and correct installation position. Clean sealing surface (2) so that it is free from oil and grease. Coat contact edges on separating face along oil sump (see arrows) with Drei Bond 1209 2.1.

Installation note: Lightly oil running surface of crankshaft.

Fit end cover (1) with support bush (2) on crankshaft and push on carefully.

Note. Graphic shows (N62TU).

Scheme 303

Insert screws (2) and initially tighten without play. Insert screws (1) and initially tighten without play. Tighten down bolts (2) from inside outwards.

Tightening torque 11 14 4AZ.

Tighten down screws (1) from inside outwards.

Tightening torque 11 13 2AZ .

Assemble engine.

11 42 260 Oil return cover

Necessary preliminary tasks

1. Remove both exhaust turbochargers . See «11 65 025 Removing and installing/replacing exhaust turbocharger, right, cylinders 1-4 (N63)»(ref-349795-S19700549122009121000000) and «11 65 030 Removing and installing/replacing exhaust turbocharger, left, cylinders 5-8 (N63)»(ref-349795-S39096168942009121000000) .
2. Remove «heat shield»(ref-349795-S27977155802009121000000) at bottom.

Release banjo bolt (1).

Tightening torque: 11 42 10AZ, see 11 42 OIL FILTER AND PIPES

Release screws (3).

Tightening torque: 11 65 6AZ, see SUPERCHARGER

Place vacuum reservoir (4) to one side.

Scheme 304

Release screws (1).

Tightening torque: 11 42 8AZ, see 11 42 OIL FILTER AND PIPES

Remove oil return cover (2).

Installation

Replace oil return cover.

Replace both O-rings.

Scheme 305

Assemble engine.

11 51 000 Removing and installing/replacing coolant pump (N63)

Recycling

Catch and dispose of drained coolant in a suitable container.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Drain coolant . See «17 00 008 DRAINING AND ADDING COOLANT IN RADIATOR (N62TU, N63)»(ref-349799-S10436053892009121000000) .
2. Remove «drive belt»(ref-349795-S09433897892009121000000) .

Unlock and detach plug connections (1).

Unlock and detach all coolant hoses on coolant pump.

Release screws (2).

Tightening torque 11 51 1AZ, see 51 71 SEALS AND LOOSE BODY PARTS

Lift out coolant pump with a swivelling movement.

Installation

Replace seal .

Scheme 306

Note. Remove coolant thermostat from faulty coolant pump. Convert coolant thermostat to new coolant pump. Tightening torque 11 53 1AZ, see THERMOSTAT AND CONNECTIONS

Installation

Replace sealing ring .

Assemble engine.

Vent cooling system and check for water leaks. See 17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR WATER LEAKS (N63) .

11 53 000 Removing and installing/replacing coolant thermostat (N63)

Recycling

Catch and dispose of drained coolant in a suitable container.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Drain coolant . See «17 00 008 DRAINING AND ADDING COOLANT IN RADIATOR (N62TU, N63)»(ref-349799-S10436053892009121000000) .
2. Remove «FAN COWL»(ref-349799-S38954538392009121000000) with electric fan.
3. Remove «INTERCOOLER EXPANSION TANK»(ref-349799-S15937990822009121000000) .
4. Remove «coolant pump»(ref-349795-S09752782762009121000000) .

Follow instructions for working on cooling system. See 17 00... INSTRUCTIONS FOR WORKING ON COOLING SYSTEM .

Release plug connector (1) and pull off.

Unlock and detach coolant hose (2).

Unfasten nut.

Release screws.

Tightening torque 11 53 1AZ, see THERMOSTAT AND CONNECTIONS

Remove coolant thermostat (3).

Scheme 307

Note. The coolant thermostat is integrated in the housing cap and can only be replaced as a complete unit.

Clean sealing surfaces.

Installation

Replace sealing ring (1) .

Scheme 308

Assemble engine.

Top up coolant .

Vent cooling system and check for water leaks.

11 53 090 Removing and installing/replacing auxiliary water pump for exhaust turbocharger (N63)

Recycling

Catch and dispose of drained coolant in a suitable container.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Remove intercooler expansion tank . See «ENGINE RADIATOR»(ref-349799-S04571686442009121000000) .

Unclip coolant hose (1) from holder in direction of arrow.

Release screws (2).

Tightening torque 11 51 4AZ, see 51 71 SEALS AND LOOSE BODY PARTS

Scheme 309

Release hose clamps (1 and 2) with a suitable tool.

Disconnect plug connection (not shown).

Scheme 310

Installation

Plug connection must snap audibly into place!

Lift out auxiliary coolant pump.

Assemble engine.

Top up coolant . See 17 00 008 DRAINING AND ADDING COOLANT IN RADIATOR (N62TU, N63) .

Venting instructions must be observed without fail . See 17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR WATER LEAKS (N63) .

17...... Removing and installing/replacing coolant pipe on cylinder head cover on left (N63)

Recycling

Catch and dispose of drained coolant.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Remove air filter housing on left . See «13 71 030 REMOVING AND INSTALLING/REPLACING BOTH INTAKE FILTER HOUSINGS (N63)»(ref-349797-S21829411552009121000000) .
2. Remove left intercooler . See «17 51 001 REMOVING AND INSTALLING/REPLACING LEFT INTERCOOLER (N63)»(ref-349799-S11197747742009121000000) or «17 51 001 REMOVING AND INSTALLING/REPLACING RIGHT INTERCOOLER (N63)»(ref-349799-S04939739542009121000000) .
3. Drain coolant . See «17 00 008 DRAINING AND ADDING COOLANT IN RADIATOR (N62TU, N63)»(ref-349799-S10436053892009121000000) .

Unlock coolant hose (1) and detach from coolant pipe.

Release screws (1).

Tightening torque 17 10 3AZ, see 17 10 COOLANT

Unclip coolant pipe (2) from holder (3).

Scheme 311

Unlock coolant hose (1) on coolant pump and detach.

Scheme 312

Pull off lug (1) on coolant pipe from crankcase.

Feed out coolant pipe (2) and remove.

Scheme 313

Assemble engine.

Check cooling system for leaks.

11 61 065 Removing and installing/replacing left intake manifold (N63)

Special tools required

1. 00 0 200

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

Necessary preliminary tasks

1. Remove complete front panel.
2. Remove complete cooling core with condenser . See «17 11 000 REMOVING AND INSTALLING RADIATOR (N63)»(ref-349799-S11977330482009121000000) .
3. Remove power steering pump with bracket. See «32 41 037 REMOVING AND INSTALLING/REPLACING POWER STEERING PUMP FOR POWER STEERING GEAR WITH DYNAMIC DRIVE (N63)»(ref-351455-S22642062662010030300000) or «32 41 033 REMOVING AND INSTALLING POWER STEERING PUMP FOR POWER STEERING GEAR WITH ACTIVE FRONT STEERING (N63)»(ref-351455-S31023533002010030300000)
4. Remove left injection pipe . See «13 53 205 REMOVING AND INSTALLING/REPLACING LEFT RAIL (N63)»(ref-349797-S23320583942009121000000) .

Detach engine ventilation hose (1).

Unscrew nuts (2).

Tightening torque: 11 61 1AZ, see INTAKE MANIFOLD

Scheme 314

Fit special tool 00 0 200.

Release nuts on left and right engine support arms.

Raise engine.

Release throttle valve (1).

Release screw (2).

Tightening torque: 11 61 2AZ, see INTAKE MANIFOLD

Installation

Replace all profile seals.

Scheme 315

Assemble engine and vehicle.

Check intake system for leaks.

11 61 068 Removing and installing/replacing right intake manifold (N63)

Special tools required

1. 00 0 200

See MAINTENANCE AND GENERAL INFORMATION - SPECIAL TOOLS .

Necessary preliminary tasks

1. Remove complete front panel.
2. Remove complete cooling core with condenser . See «17 11 000 REMOVING AND INSTALLING RADIATOR (N63)»(ref-349799-S11977330482009121000000) .
3. Remove power steering pump with bracket. See «32 41 033 REMOVING AND INSTALLING POWER STEERING PUMP FOR POWER STEERING GEAR WITH ACTIVE FRONT STEERING (N63)»(ref-351455-S31023533002010030300000) or «32 41 037 REMOVING AND INSTALLING/REPLACING POWER STEERING PUMP FOR POWER STEERING GEAR WITH DYNAMIC DRIVE (N63)»(ref-351455-S22642062662010030300000) .
4. Remove right injection pipe . See «13 53 205 REMOVING AND INSTALLING/REPLACING LEFT RAIL (N63)»(ref-349797-S23320583942009121000000) .

Detach engine ventilation hose (1).

Unscrew nuts (2).

Tightening torque: 11 61 1AZ, see INTAKE MANIFOLD

Scheme 316

Fit special tool 00 0 200.

Scheme 317

Release nuts on left and right engine support arms.

Raise engine.

Remove throttle valve (2).

Release screw (1).

Tightening torque: 11 61 2AZ, see INTAKE MANIFOLD

Installation

Replace all profile seals.

Scheme 318

Assemble engine and vehicle.

Check intake system for leaks.

Necessary preliminary work

1. Release upper section of intake air filter.
2. Prepare BMW diagnosis system.
3. Start diagnostic program. Power train Engine electronics Air supply Charging pressure control Oder Perception Lack of power

Note on ordering

1. Workshop equipment.
2. Workshop planning.
3. Workshop equipment catalogue.
4. Measuring and test equipment.
5. No. 81 29 0 426 464

Pressure measurement

Prepare BMW diagnosis system on excess pressure diagnosis unit.

Scheme 319

1. Screw in pressure sensor.
2. Overpressure connection (Blue).
3. Connect stimuli cables (3) to positive and negative.
4. Connect 12V battery cables (4) to vehicle battery positive and negative.

Secure seal plug (1) with union nut (2) in intake port and seal.

Note. Twin-Turbo: both intake ports must be sealed.

Scheme 320

Insert Blue pneumatic hose (4) in pneumatic coupling (2) of sealing plug (1).

Seal plug (3) has no pneumatic coupling.

Scheme 321

Vacuum pressure measurement

Prepare diagnosis tester on vacuum diagnosis unit.

Scheme 322

1. Screw in pressure sensor.
2. Connect stimuli cables (2) to positive and negative.
3. Connect 12V battery cables (3) to vehicle battery positive and negative.
4. Controller for vacuum connection.
5. Vacuum connection (Red).

Vacuum activation, cylinders 1-4

Detach red vacuum line from vacuum unit.

Prepare T-piece (5) with vacuum lines for measurement.

Connect red vacuum line (1) with vacuum unit (2) and quick-release coupling (3).

Open shutoff tap (4).

Note. Observe diagnosis instructions.

Scheme 323

Vacuum activation, cylinders 5-8

Detach blue vacuum line from vacuum unit.

Prepare T-piece (5) with vacuum lines for measurement.

Connect blue vacuum line (1) with vacuum unit (2) and quick-release coupling (3).

Open shutoff tap (4).

Note. Observe diagnosis instructions.

Scheme 324

Exhaust turbocharger, cylinders 1-4

Initial position (1) of wastegate linkage depressurized.

Wastegate valve opened.

Scheme 325

Initial position (1) of wastegate linkage with vacuum pressure.

Wastegate valve closed.

Scheme 326

Exhaust turbocharger, cylinders 5-8

Initial position (1) of wastegate linkage depressurized.

Wastegate valve opened.

Scheme 327

Initial position (1) of wastegate linkage with vacuum pressure.

Wastegate valve closed.

Scheme 328

Check wastegate valve with vacuum

Wastegate valves must be opened without vacuum.

The wastegate valves must close if a vacuum pressure is applied at the wastegate sockets (see BMW diagnosis system).

Check shaft on turbine wheel for rotatability.

Scheme 329

Follow diagnosis instructions.

Scheme 330

1. Connection (1) black to exhaust flaps.
2. Distributor element (2), vacuum pump / vacuum reservoir (4).
3. Vacuum line (3) black to vacuum pump.
4. Vacuum reservoir (4) with three connections.
5. Connection, vacuum unit (wastegate), bank 2, cylinders 5 to 8.
6. Connection, vacuum unit (wastegate), bank 1, cylinders 1 to 4.
7. Vacuum hose (7) black / blue to connection, vacuum unit, (5) to pressure transducer (OUT), bank 2, cylinders 5 to 8.
8. Vacuum hose black to connection, vacuum reservoir, to pressure transducer (VAC), bank 2, cylinders 5 to 8.
9. Vacuum hose (9) black / red to connection, vacuum unit, (6) to pressure transducer (OUT), bank 1, cylinders 1 to 4.
10. Vacuum hose black to connection, vacuum reservoir, to pressure transducer (VAC), bank 1, cylinders 1 to 4.

11 65 010 Removing and installing/replacing pressure accumulator (N63)

Necessary preliminary tasks

1. Remove both exhaust turbochargers . See «11 65 025 Removing and installing/replacing exhaust turbocharger, right, cylinders 1-4 (N63)»(ref-349795-S19700549122009121000000) and «11 65 030 Removing and installing/replacing exhaust turbocharger, left, cylinders 5-8 (N63)»(ref-349795-S39096168942009121000000) .
2. Remove both exhaust manifolds . See «18 40 020 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST MANIFOLD (N63)»(ref-349800-S00656944592009121000000) .
3. Remove «heat shield»(ref-349795-S27977155802009121000000) at bottom.

Release banjo bolt (1).

Tightening torque 11 42 3AZ, see 11 42 OIL FILTER AND PIPES

Installation

Replace sealing ring .

Release screw (3) on engine oil line.

Remove engine oil line (2).

Release screws (3) on vacuum reservoir (4).

Tightening torque 11 65 6AZ, see SUPERCHARGER

Remove vacuum reservoir (4).

Check vacuum connections for correct routing.

Check vacuum system for leaks.

Assemble engine.

11 65 025 Removing and installing/replacing exhaust turbocharger, right, cylinders 1-4 (N63)

Necessary preliminary tasks

1. Remove catalytic converter , cylinders 1-4. See «18 32 050 REMOVING AND INSTALLING/REPLACING CATALYTIC EXHAUST GAS CONVERTER, CYLINDERS 1-4 (N63)»(ref-349800-S23537616362009121000000) .

Disconnect plug connection (1) on electric changeover valve (2).

Scheme 331

Release screw (1).

Tightening torque 11 42 7AZ, see 11 42 OIL FILTER AND PIPES

Unfasten banjo bolt (2).

Tightening torque 11 42 4AZ, see 11 42 OIL FILTER AND PIPES

Lay oil line (3) from turbocharger to side.

Installation

Replace all sealing rings .

Scheme 332

Release screw (1).

Tightening torque 11 53 3AZ, see THERMOSTAT AND CONNECTIONS

Release banjo bolt (2).

Tightening torque 11 53 2AZ, see THERMOSTAT AND CONNECTIONS

Lay coolant return line (3) to one side.

Installation

Replace all sealing rings .

Scheme 333

Open hose clip (1).

Detach coolant feed line (2).

Installation

Replace hose clamp (1) .

Scheme 334

Release screw (1) with a suitable tool.

Note. Oil return pipe (2) can only be removed with turbocharger.

Tightening torque 11 42 10AZ, see 11 42 OIL FILTER AND PIPES

Scheme 335

Release screw (4).

Open V-band clamp (3).

Remove turbocharger with oil return line in upward direction.

Scheme 336

If necessary, convert coolant feed line to new turbocharger.

Release banjo bolt (1).

Tightening torque 11 53 2AZ, see THERMOSTAT AND CONNECTIONS

Scheme 337

Release screw (1).

Tightening torque 11 53 3AZ, see THERMOSTAT AND CONNECTIONS

Modify coolant feed line (2).

Scheme 338

Release screws (1).

Tightening torque 11 42 9AZ, see 11 42 OIL FILTER AND PIPES

Remove oil return pipe (2).

Installation

Replace seal .

Scheme 339

The thermal linear compensators (see arrows) on the oil return pipe (1) must not be mechanically deformed.

Installation

Moisten oil return pipe at end with engine oil.

Scheme 340

Installation

Replace O-rings on oil return cover (2).

Note. Picture shows turbocharger removed.

Installation

Replace gasket on exhaust manifold .

Installation

Check locating apparatus on exhaust manifold.

Scheme 341

Position turbocharger with oil return line on exhaust manifold.

Position V-band clamp (3).

Insert bolt (4).

Tightening torque 11 65 1AZ, see SUPERCHARGER

Installation

The ends of the V-band clamp must rest parallel to each other.

Tightening torque 11 65 1AZ, see SUPERCHARGER

Scheme 342

Screw connection of V-band clamp is too loose

If you can see a gap between the ends of the V-band clamps, release and then repeat the screw connection.

Tightening torque 11 65 1AZ, see SUPERCHARGER

Scheme 343

Screw connection of V-band clamp is too tight

If the ends of the V-band clamp are positioned under each other, release and then repeat the screw connection.

Tightening torque 11 65 1AZ, see SUPERCHARGER

Scheme 344

Scheme 345

Assemble engine.

Check vacuum connections .

Observe BMW diagnosis instructions.

1. Complete vehicle
2. Drive
3. Engine electrics
4. Air supply
5. Boost pressure control

11 65 030 Removing and installing/replacing exhaust turbocharger, left, cylinders 5-8 (N63)

Necessary preliminary tasks

1. Remove catalytic converter , cylinders 5-8. See «18 32 050 REMOVING AND INSTALLING/REPLACING CATALYTIC EXHAUST GAS CONVERTER, CYLINDERS 5-8 (N63)»(ref-349800-S41027185382009121000000) .

Disconnect plug connection (1) on electric changeover valve (2).

Scheme 346

Release screw (1).

Tightening torque 11 42 7AZ, see 11 42 OIL FILTER AND PIPES

Unfasten banjo bolt (2).

Tightening torque 11 42 4AZ, see 11 42 OIL FILTER AND PIPES

Lay oil line from turbocharger to side.

Installation

Replace all sealing rings .

Scheme 347

Release screw (1).

Tightening torque 11 53 3AZ, see THERMOSTAT AND CONNECTIONS

Release banjo bolt (2).

Tightening torque 11 53 2AZ, see THERMOSTAT AND CONNECTIONS

Lay coolant return line to one side.

Installation

Replace all sealing rings .

Scheme 348

Open hose clip (1).

Detach coolant feed line (2).

Installation

Replace hose clamp (1) .

Scheme 349

Release screw (4) with a suitable tool.

Note. Oil return pipe (3) can only be removed with turbocharger.

Tightening torque 11 42 10AZ, see 11 42 OIL FILTER AND PIPES

Release screw (1).

Open V-band clamp (2).

Remove turbocharger with oil return line in upward direction.

If necessary, convert coolant feed line to new turbocharger.

Release banjo bolt (1).

Tightening torque 11 53 2AZ, see THERMOSTAT AND CONNECTIONS

Release screw (1).

Tightening torque 11 53 3AZ, see THERMOSTAT AND CONNECTIONS

Modify coolant feed line (2).

Release screws (1).

Tightening torque 11 42 9AZ, see 11 42 OIL FILTER AND PIPES

Remove oil return pipe (2).

Installation

Replace seal .

The thermal linear compensators (see arrows) on the oil return pipe (1) must not be mechanically deformed.

Installation

Moisten oil return pipe at end with engine oil.

Installation

Replace O-rings on oil return cover (2) .

Note. Picture shows turbocharger removed.

Replace gasket (1) on exhaust manifold.

Installation

Check locating apparatus on exhaust manifold.

Scheme 350

Position turbocharger with oil return line on exhaust manifold.

Position V-band clamp (2).

Insert screw (1).

Tightening torque 11 65 1AZ, see SUPERCHARGER

Installation

The ends of the V-band clamp must rest parallel to each other.

Tightening torque 11 65 1AZ, see SUPERCHARGER

Screw connection of V-band clamp is too loose

If you can see a gap between the ends of the V-band clamps, release and then repeat the screw connection.

Tightening torque 11 65 1AZ, see SUPERCHARGER

Screw connection of V-band clamp is too tight

If the ends of the V-band clamp are positioned under each other, release and then repeat the screw connection.

Tightening torque 11 65 1AZ, see SUPERCHARGER

Vacuum hose (1) Black/Blue for cylinders 5-8

Assemble engine.

Check vacuum connections .

Observe BMW diagnosis instructions.

1. Complete vehicle
2. Drive
3. Engine electrics
4. Air supply
5. Boost pressure control

11 65 165 Removing and installing/replacing blow-off valve (N63)

Necessary preliminary tasks

1. Remove «exhaust turbocharger, right, cylinders 1-4 (N63)»(ref-349795-S19700549122009121000000) and «exhaust turbocharger, left, cylinders 5-8 (N63)»(ref-349795-S39096168942009121000000) .

Release screws (1). Tightening torque 11 65 9 AZ . Remove blow-off valve (2).

Scheme 351

Check vacuum connections for correct routing.

Check vacuum system for leaks.

11 65 180 Removing and installing/replacing heat shield at top (N63)

Necessary preliminary tasks

1. Remove both intake filter housings . See «13 71 030 REMOVING AND INSTALLING BOTH INTAKE FILTER HOUSINGS (N63)»(ref-349797-S00938821222009121000000) .
2. Remove «left control sensor»(ref-349795-S36599499572009121000000) and «right control sensor»(ref-349795-S32994371052009121000000) .

Release screws (1).

Lift out holder.

Scheme 352

Release screw (2).

Tightening torque 11 65 3AZ, see SUPERCHARGER

Scheme 353

Release screw (2).

Tightening torque 11 65 3AZ, see SUPERCHARGER

Scheme 354

Release retaining clip (1).

Detach wire ring (2) and set down behind oxygen sensor.

Scheme 355

Release retaining clip (1).

Detach wire ring (2) and set down behind oxygen sensor.

Scheme 356

Release screws (1).

Tightening torque 11 65 3AZ, see SUPERCHARGER

Note. For purposes of clarity, the graphic shows the oxygen sensor removed.

Scheme 357

Release screws (1).

Tightening torque 11 65 3AZ, see SUPERCHARGER

Lift out heat shield.

Scheme 358

Assemble engine.

11 65 185 Removing and installing/replacing heat shield at bottom (N63)

1. Disconnect battery lead from negative terminal . See «BATTERY»(ref-351441-S18688541382009122100000) .
2. Remove fan cowl with electric fan. See «17 11 035 REMOVING AND INSTALLING/REPLACING FAN COWL WITH ELECTRIC FAN (N63)»(ref-349799-S38954538392009121000000) .
3. Remove alternator . See «12 31 020 REMOVING AND INSTALLING OR REPLACING ALTERNATOR (N63)»(ref-349796-S12957128002009121000000) .
4. Remove both exhaust turbochargers . See «11 65 025 Removing and installing/replacing exhaust turbocharger, right, cylinders 1-4 (N63)»(ref-349795-S19700549122009121000000) and «11 65 030 Removing and installing/replacing exhaust turbocharger, left, cylinders 5-8 (N63)»(ref-349795-S39096168942009121000000) .
5. Remove both exhaust manifolds . See «18 40 020 REMOVING AND INSTALLING/REPLACING RIGHT EXHAUST MANIFOLD (N63)»(ref-349800-S00656944592009121000000) .

Release screws (1).

Tightening torque 11 65 3AZ, see SUPERCHARGER

Scheme 359

Release screws (1).

Tightening torque 11 65 3AZ, see SUPERCHARGER

Remove heat shield (2) towards top.

Scheme 360

Release screws (1).

Tightening torque 11 65 3AZ, see SUPERCHARGER

Scheme 361

Release front screws on heat shield (1).

Tightening torque 11 65 3AZ, see SUPERCHARGER

Remove heat shield (1) towards top.

Scheme 362

Assemble engine.

11 65 712 Removing and installing/replacing electric changeover valve on exhaust turbocharger, left (N63)

Necessary preliminary tasks

1. Remove left «turbocharger»(ref-349795-S39096168942009121000000) .

Release screws (1).

Remove electric changeover valve.

Installation

Replace O-ring.

Scheme 363

Assemble engine.

Follow diagnosis instruction.

1. Complete vehicle
2. Drive
3. Engine electrics
4. Air supply
5. Boost pressure control

11 65 714 Removing and installing/replacing electric changeover valve on exhaust turbocharger, right (N63)

Necessary preliminary tasks

1. Remove right «turbocharger»(ref-349795-S19700549122009121000000) .

Release screws (1).

Remove electric changeover valve (2).

Installation

Replace O-ring.

Scheme 364

Assemble engine.

Follow diagnosis instruction.

1. Complete vehicle
2. Drive
3. Engine electrics
4. Air supply
5. Boost pressure control

11 66 000 Removing and installing/replacing vacuum pump (N63)

Vacuum pump is fitted on cylinder head 1 to 4 at rear on inlet camshaft.

Necessary preliminary tasks

1. Press brake pedal several times in order to reduce vacuum pressure in brake booster.
2. Remove right catalytic converter.
3. Remove right heat shield.
4. Detach vacuum line from vacuum pump. Release screws (1). Remove heat shield (2). Remove vacuum hose.

Scheme 365

Release screws (1).

Note. Bolts (1) are secured against falling out.

Release screw (2).

Remove vacuum pump (3).

Scheme 366

Drive (1) must be rotated into correct position prior to installation.

Installation

Replace sealing ring (2) and coat with grease to facilitate fitting.

Scheme 367

Installation

Align vacuum pump drive to groove (1) of intake camshaft.

Vacuum pump can best be installed when groove (1) is vertically aligned.

Scheme 368

Check function of DME.

Check vacuum pump for leaks and correct operation.

11 74 509 Replacing both pressure converters for turbocharger (N63)

Necessary preliminary tasks

1. Partially release intercooler expansion tank . See «ENGINE RADIATOR»(ref-349799-S04571686442009121000000) .
2. Partially release auxiliary «coolant pump»(ref-349795-S38127875862009121000000) for turbocharger.
3. Disconnect plug connection on «coolant thermostat»(ref-349795-S40884699502009121000000) .

Pressure converter, cylinders 1-4

Disconnect plug connection (1) on pressure converter.

Installation

Plug connection (1) must snap audibly into place!

Disconnect black vacuum hose at connection (VAC = vacuum reservoir).

Disconnect black/red vacuum hose at connection (OUT = turbocharger vacuum unit).

Unscrew nuts (2).

Tightening torque 11 65 8AZ, see SUPERCHARGER

Remove pressure converter.

Scheme 369

Pressure converter, cylinders 5-8

Disconnect plug connection (1) on pressure converter.

Installation

Plug connection (1) must snap audibly into place!

Disconnect black vacuum hose at connection (VAC = vacuum reservoir).

Scheme 370

Disconnect black/blue vacuum hose at connection (OUT=turbocharger vacuum unit).

Unscrew nuts (2).

Tightening torque 11 65 8AZ, see SUPERCHARGER

Remove pressure converter.

Check activation via BMW diagnosis system.

11 78 530 Replacing left control sensor (N63)

Special tools required

1. 11 7 020

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Check function of DME control unit
2. Switch off ignition
3. Remove air filter housing . See «13 71 030 REMOVING AND INSTALLING BOTH INTAKE FILTER HOUSINGS (N63)»(ref-349797-S00938821222009121000000) .

Unlock plug connection and detach.

Unclip control sensor cable at retaining clips.

Release control sensor with special tool 11 7 020.

Scheme 371

Installation

The threads of new lambda control/monitor sensors are already coated with Never Seez Compound

If a lambda control/monitor sensor is to be reused, apply a thin and even coating of Never Seez Compound to the thread only.

The part of the lambda control/monitor sensor which projects into the exhaust system branch (sensor ceramics) must not be cleaned and not coated with lubricant.

Secure control sensor with special tool 11 7 020 and a torque wrench (1).

Tightening torque 11 78 1AZ, see EMISSION CONTROL

Installation

Check function of DME control unit.

Pay attention to cable routing of control sensor.

11 78 533 Replacing right control sensor (N63)

Special tools required

1. 11 7 020

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Check function of DME control unit
2. Switch off ignition
3. Remove air filter housing . See «13 71 030 REMOVING AND INSTALLING BOTH INTAKE FILTER HOUSINGS (N63)»(ref-349797-S00938821222009121000000) .

Unlock plug connection and detach.

Unclip control sensor cable from holder.

Release control sensor with special tool 11 7 020.

Scheme 372

Installation

The threads of new lambda control/monitor sensors are already coated with Never Seez Compound

If a lambda control/monitor sensor is to be reused, apply a thin and even coating of Never Seez Compound to the thread only.

The part of the lambda control/monitor sensor which projects into the exhaust system branch (sensor ceramics) must not be cleaned and not coated with lubricant.

Secure control sensor with special tool 11 7 020 and a torque wrench (1).

Tightening torque 11 78 1AZ, see EMISSION CONTROL

Installation

Check function of DME control unit.

Pay attention to cable routing of control sensor.

11 78 540 Replacing left monitor sensor (N63)

Special tools required

1. 11 7 020

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Check function of DME control unit
2. Switch off ignition
3. Remove air filter housing . See «13 71 030 REMOVING AND INSTALLING BOTH INTAKE FILTER HOUSINGS (N63)»(ref-349797-S00938821222009121000000) . Release retaining clip (1). Remove heat shield wire ring (2) over oxygen sensor. Detach oxygen sensor cable from retaining clips (3).

Scheme 373

Release monitor sensor (1) with special tool 11 7 020.

Scheme 374

Installation

The threads of new lambda control/monitor sensors are already coated with Never Seez Compound.

If a lambda control/monitor sensor is to be reused, apply a thin and even coating of Never Seez Compound to the thread only.

The part of the lambda control/monitor sensor which projects into the exhaust system branch (sensor ceramics) must not be cleaned and not coated with lubricant.

Secure monitor sensor (1) with special tool 11 7 020.

Tightening torque 11 78 1AZ, see EMISSION CONTROL

Installation

Check function of DME control unit.

Pay attention to cable routing of monitor sensor.

11 78 543 Replacing right monitor sensor (N63)

Special tools required

1. 11 7 020

See ENGINE - SPECIAL TOOLS (N54, N63) .

Necessary preliminary tasks

1. Check function of DME control unit
2. Switch off ignition
3. Remove air filter housing . See «13 71 030 REMOVING AND INSTALLING BOTH INTAKE FILTER HOUSINGS (N63)»(ref-349797-S00938821222009121000000) .

Release retaining clip (1).

Remove heat shield (2) over oxygen sensor.

Detach oxygen sensor cable from retaining clips (3).

Release monitor sensor (1) with special tool 11 7 020.

Scheme 375

Installation

The threads of new lambda control/monitor sensors are already coated with Never Seez Compound.

If a lambda control/monitor sensor is to be reused, apply a thin and even coating of Never Seez Compound to the thread only.

The part of the lambda control/monitor sensor which projects into the exhaust system branch (sensor ceramics) must not be cleaned and not coated with lubricant.

Secure monitor sensor (1) with special tool 11 7 020.

Tightening torque 11 78 1AZ, see EMISSION CONTROL

Installation

Check function of DME control unit.

Pay attention to cable routing of monitor sensor.