Engine - Repair Instructions (m44) BMW Z3 E36

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.

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 00 249 BMW engine oil service (M40 / M42 / M43 / M43TU / M44)

Change engine oil and oil filter.

Version with central screw

Unscrew oil-filter cover

Oil flows from oil-filter housing into oil pan.

Installation

Replace sealing ring.

Tightening Torque, refer to 11 42 2AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Scheme 55

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

Scheme 56

Remove oil filter insert.

Scheme 57

Version with screw cap

Loosen the oil filter cap using special tool 11 7 331. See ENGINE - SPECIAL TOOLS (M44) .

Oil flows from oil-filter housing into oil pan.

Tightening Torque, refer to 11 42 2AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Scheme 58

Replace seals and coat with oil.

Scheme 59

After draining oil from oil-filter housing, unscrew oil drain plug or draw out oil with a vacuum unit.

Replace sealing ring.

Tightening Torque, refer to 11 13 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Scheme 60

Pour in engine oil.

Start engine and allow to idle until oil indicator light goes out.

Stop engine and check oil level.

11 00 039 Checking compression of all cylinders (M40 / M42 / M43 / M43TU / M44)

1. Read out fault memory of DME control unit
2. Check stored faults
3. Rectify faults
4. Clear fault memory

Disconnect DME relay (K6300).

E46 installation location

1. Connect DIS Tester
2. Select Diagnosis
3. Carry out vehicle identification
4. Function selection
5. Component and signal function
6. Components
7. Relays
8. DME relay
9. Documents
10. Installation location (IL)
11. Displays

Remove all spark plugs.

Screw special tool 11 0 226 by hand into spark plug thread and connect special tool 11 0 224. See ENGINE - SPECIAL TOOLS (M44) .

Note. Check that seal is in perfect condition.

Scheme 61

Depress accelerator and actuate starter until compression stops rising.

Compression pressure, refer to ENGINE - TECHNICAL DATA (M44) .

Scheme 62

Now clear the fault memory.

Scheme 63

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

Special tools required

1. 11 0 070 . See «ENGINE - SPECIAL TOOLS (M44)»(/bmw/z3/e36-1995-2000/remont/mechanical/#engine-special-tools-m44) . Disconnect negative battery lead. Remove the ignition coil from the spring strut dome.

E36

Lift engine hood into assembly position and remove firewall (air manifold).

Z3

Move engine hood to assembly position

Note. The following work must be carried out with a second person assisting. Work instruction applies to left and right sides. Hold engine bonnet/hood. Unclip retainer (1). Unhook damper and suspend in ball head (2).

Scheme 64

Remove Bowden cable for throttle actuation from throttle.

Remove suction filter housing.

Remove fan clutch with fan impeller.

Remove radiator.

Disconnect heater hoses at heater and heating valve.

Scheme 65

Release oil tank for hydraulic steering and tie back to one side.

Note. Lines remain connected.

Scheme 66

Unfasten vane pump for power steering unit from alternator carrier and tie up to one side (lines remain connected).

Remove manifold lower section.

Unfasten the wire harness section for the engine.

Loosen fuel supply line and return line.

Remove transmission. See appropriate article in TRANSMISSION section.

Attach engine to special tool 11 0 070.

Scheme 67

Unfasten right ground wire.

Unscrew left and right engine mounts.

Automatic transmission

Release oil lines from engine carrier and from oil sump.

Lift out engine.

Scheme 68

Engine identification

Drive in engine numbers at marked surface with impact tool.

M47 / M47TU / M47T2

Scheme 69

M57 / M57TU / M57T2

Scheme 70

M67 / M67TU

Scheme 71

N47 / N47S

Scheme 72

M52 / M52TU

Scheme 73

M54

Scheme 74

M56

Scheme 75

N40 / N45 / N45T / N43

Scheme 76

N42 / N46 / N46T

Scheme 77

N51 / N52 / N52K / N53 / N54

Scheme 78

N62

Scheme 79

N73

Scheme 80

S54

Scheme 81

S85 / S65

Scheme 82

W10 / W11

Scheme 83

W17

Scheme 84

Assemble engine.

11 12 000 Removing and installing/sealing cylinder head cover (M44)

Disconnect the battery ground cable and the battery positive cable.

Remove the ignition coil from the spring strut dome.

Remove battery.

Loosen the screws and remove the battery bracket.

Scheme 85

Slightly lift the grille and loosen the cable duct from the end firewall (air manifold). Pull the cable duct upwards.

Scheme 86

Take off cover.

Scheme 87

Remove spark-plug connectors.

Scheme 88

Loosen the ignition lead and remove it with the cable duct.

Scheme 89

Pull off the hose for the engine breather.

Unscrew cover bolts and remove cylinder head cover.

Scheme 90

Note. Cylinder head cover is separated from cylinder head by rubber mounts and seals to insulate it from vibration.

Carefully note arrangement of cover retaining fixture.

1. Cap screw
2. Washer
3. Rubber mount

Scheme 91

Check cylinder-head-cover seal and replace if necessary.

Pre-install cylinder-head-cover seal at cylinder head cover.

Scheme 92

Clean gasket residue from sealing surfaces.

Coat contact surfaces of joint with Drei Bond 1209.

Scheme 93

Clean gasket residue from sealing surfaces.

Apply a thin, uniform bead of Drei Bond 1209 sealing agent to transition area of half-moon sections.

Scheme 94

Scheme 95

When installing cylinder head cover, make sure that cylinder head cover seal is correctly seated on rear side of cylinder head.

Install cover bolts and align cylinder head cover. Hand-tighten all cover bolts without preload. Tighten cap screws crosswise from inside to outside.

Tightening torque, refer to 11 12 11AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Scheme 96

11 12 100 Removing and installing cylinder head (M44)

Remove suction-filter housing with air-mass sensor.

Remove gear-case cover, top, refer to 11 14 100 Removing and installing, sealing or replacing timing case cover at top (M44)

Remove all spark plugs.

Drain coolant from engine block.

Replace sealing ring.

Tightening torque, refer to 11 11 5AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Scheme 97

Remove exhaust pipe from exhaust manifold.

Remove lower section of manifold, refer to 11 61 044

Remove the hydraulic chain tensioner, refer to 11 31 091

Release water hose from rear branch flange.

Disconnect heater feed and return hoses.

Removal

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

Turn central screw to rotate crankshaft in normal direction of rotation until piston of first cylinder is at firing TDC.

Scheme 98

Note. At firing TDC, alignment bores are pointing upwards.

Scheme 99

Position camshaft with Special Tool 11 3 240 in firing TDC position of first cylinder.

Scheme 100

Remove the chain wheels.

Scheme 101

Release the slide rail from the cylinder head.

Scheme 102

Turn the adjusting screw of the slide rail back approx. two revolutions.

Scheme 103

This prevents contact between valves and pistons.

Note. Use Special Tool 11 2 250. See ENGINE - SPECIAL TOOLS (M44) .

Release cylinder-head bolts in sequence 10 ... 1.

Remove cylinder head and cylinder-head seal.

Scheme 104

Installation of cylinder head is described separately from removal. Assembly sequence for removal and installation is different.

Clean sealing faces of cylinder head and engine block; if necessary, remove traces of sealing compound with hardwood spatula. Ensure that no gasket debris drops into the oil and coolant ducts.

Check that dowel sleeves are undamaged and correctly located.

Replace cylinder-head seal and rubber-profile seal.

Scheme 105

Threaded bores in engine block must be free of dirt and oil.

Note. Risk of cracking, incorrect tightening values.

Put the cylinder head on.

Install the new cylinder-head bolts (lightly oiled).

For torsion angle adjustment, use Special Tool 00 9 120 or Special Tool 11 2 110.

Scheme 106

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

Tightening torque, refer to 11 12 6AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Place the adjusting screw of the slide rail free of play on the cylinder head.

Insert the screw and tighten down the slide rail.

Locate camshaft with Special Tool 11 3 240 in firing TDC position of first cylinder.

Note. At firing TDC, alignment bores are pointing upwards.

Remove dust cover from locating bore.

Scheme 107

Rotate engine from 45° before TDC position engine-wise until in TDC position.

Secure crankshaft in TDC position with Special Tool 11 2 300.

Scheme 108

Place the chain with the chain wheels.

Note. Arrow on chain wheel in cylinder axis points up. Align long bores centrally.

Scheme 109

Place the sensor gear onto the inlet chain wheel.

Note. Arrow on sensor gear in cylinder axis points up.

Scheme 110

Insert all chain wheel screws and tighten so that they are free of play; the chain wheels remain loose.

Install hydraulic chain tensioner.

refer to 11 31 091

Tighten down the chain wheels.

For tightening torque, refer to 11 31 3AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Remove Special Tools 11 2 300 and 11 3 240.

Assemble engine.

11 12 101 Replacing cylinder-head seal (M44)

See removing and installing cylinder head in 11 12 100

11 12 503 Dismantling and reassembling cylinder head (M44)

(cylinder head removed)

Remove exhaust manifold.

Coat threads with copper paste CRC.

Replace the gasket and nuts.

Tightening torque, refer to 11 62 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Screw in Special Tool 11 1 442.

Scheme 111

Secure Special Tool 11 1 065 to Special Tool 00 1 490.

Prepare Special Tools for cylinder-head disassembly

Scheme 112

1. Special Tool 11 1 071
2. Special Tool 11 1 067
3. Special Tool 11 0 192. See «ENGINE - SPECIAL TOOLS (M44)»(/bmw/z3/e36-1995-2000/remont/mechanical/#engine-special-tools-m44) .
4. Special Tool 11 1 045
5. Special Tool 11 0 345
6. Special Tool 11 0 342
7. Special Tool 11 0 343
8. Special Tool 11 1 441

Assemble Special Tool. See ENGINE - SPECIAL TOOLS (M44) .

Scheme 113

Note. Do not install Special Tool 11 1 441 (locating board) in Special Tool 11 1 065 at this stage.

Scheme 114

Fit cylinder head with exhaust end pointing forwards and right on Special Tool 11 1 065 and secure with two cylinder head screws.

Scheme 115

Remove all valves, refer to 11 34 552

11 12 527 Reworking one valve seat (M44)

(cylinder head dismantled)

Machine valve seat face with Special Tool 00 3 520 or 00 3 580 with specifications of tool manufacturer.

Scheme 116

Note. After machining the valve-seat face on OD and bore diameter, rework to specified diameter with correction milling tool until valve seat width (5) is obtained.

1. Valve-seat angle
2. Correction angle, outer
3. Correction angle, inner
4. Outside diameter of seat face
5. Valve-seat width

Pos. (1) to (5) refer to ENGINE - TECHNICAL DATA (M44)

Scheme 117

11 12 595 Checking one valve guide for wear (M44)

(valve removed)

To measure tilt clearance, insert new valve so that valve stem end is flush with valve guide.

Mount dial gauge and measure tilt clearance.

Note. Maximum permitted tilt clearance

refer to ENGINE - TECHNICAL DATA (M44)

Scheme 118

Note. If tilt clearance is excessive, the valve guide should be reamed and a repair valve with a larger shaft diameter

refer to ENGINE - TECHNICAL DATA (M44) , should be installed.

Scheme 119

If necessary, ream out valve guide, refer to 11 12 600

11 12 600 Reaming out one valve guide (M44)

(Valve removed)

Note. If clearance between valve shaft and valve guide is too large, ream out valve guide and install repair valve with larger shaft diameter.

Assemble reaming tool and guide taper (1) from special tool kit 00 4 210 depending on shaft diameter. Press guide taper (1) against valve seat and ream out valve guide (when dry) from combustion-chamber end. Rotate reaming tool once in downwards direction.

Note. After the reaming operation, rework the valve seat

refer to 11 12 527

Scheme 120

11 12 719 Mill down cylinder head sealing face (M44)

(cylinder head dismantled)

Check evenness of cylinder-head surface with straight edge (commercially available).

Deviation from level: max. 0.05 mm.

Note. Machine limit

refer to ENGINE - TECHNICAL DATA (M44)

Scheme 121

11 12 729 Check cylinder head for water leaks (M44)

(cylinder head dismantled)

Seal coolant apertures with Special Tool kit 11 1 440.

Note. Remove the temperature sensor for the coolant and replace with Special Tool 11 1 439 (drain plug).

Scheme 122

Immerse cylinder head in a water bath.

Test pressure 4.5 bar

Check cylinder head for escaping air (cracks).

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

Scheme 123

11 34 552 Removing and installing or replacing all valves - cylinder head removed (M44)

Preliminary work is described in section on dismantling and assembling the cylinder head, refer to 11 12 503

Replacing valve stem seals, refer to 11 34 560

Remove valves from cylinder head.

If necessary, check valve guide for wear, refer to 11 12 595

If necessary, ream the valve guide, refer to 11 12 600

If necessary, rework valve seat, refer to 11 12 527

Installation sequence

1. Valve
2. Valve-stem seal
3. Lower plate spring
4. Valve spring
5. Upper plate spring
6. Valve tapers

Scheme 124

11 34 560 Replacing all valve-shaft seals - cylinder head removed (M44)

Preliminary work is described in section on dismantling and assembling the cylinder head, refer to 11 12 503

Remove all valve springs, refer to 11 34 715

Remove valve stem seal with Special Tool 11 1 480.

Scheme 125

Lubricate valve stem with oil and insert valve.

Fit Special Tool 11 1 960.

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

Scheme 126

Press valve stem seal firmly home by hand with Special Tool 11 1 200.

Scheme 127

11 34 715 Replacing all valve springs - cylinder head removed (M44)

Preliminary work is described in section on dismantling and assembling the cylinder head, refer to 11 12 503

Remove the camshafts, refer to 11 31 501

Insert Special Tool 11 1 441 from below in Special Tool 11 1 065 and secure with Special Tool 11 1 045.

Scheme 128

Align Special Tool 11 0 345 in direction of valve shaft and select appropriate groove in Special Tool 11 0 342.

Scheme 129

Press down valve spring on spring cap, top, and remove valve keys.

Remove valve spring and plate spring.

Scheme 130

Installation sequence

1. Valve
2. Valve-stem seal
3. Lower plate spring
4. Valve spring
5. Upper plate spring
6. Valve tapers

11 13 000 Removing and installing, sealing or replacing oil pan (M44)

Note. For removal of oil pan, front axle support must be lowered. There is no need to perform a front axle alignment check. Draining off engine oil, refer to 00 00 249

Disconnect adapter from brake booster.

Scheme 131

Loosen guide pipe for dipstick.

Scheme 132

Check/replace sealing ring.

Scheme 133

E36/7 (Z3)

Measure and note down left and right protrusion of detent buffer (1). Remove left and right detent buffers (1).

Reinstall detent buffers (1) to noted dimension.

Scheme 134

Unclip cable and lines and place to one side.

Attach special tool 00 0 200 to special tool 00 0 201/202/204/207.

Note. Special tool 00 0 207 is secured in bore of detent buffer and behind the carrier support beside the spring dome.

Scheme 135

Fit special tool 00 0 200, secure to front suspension lug on engine and lift engine approx. 5 mm.

Scheme 136

All other E36 models

Fit special tool 00 0 200 to special tool 00 0 201/202/204/206 and attach.

Note. The brackets must be located on the bolt connections on both side walls. Attach special tool 00 0 200 to front suspension lug on engine and lift engine approx. 5 mm.

Scheme 137

Unfasten steering spindle from steering gear.

Unscrew engine mountings on bottom left and right.

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

Scheme 138

Unfasten left and right control arm from engine carrier.

Unfasten screw connection on front axle support and lower the front axle support.

Note. The steering gear must not be disconnected from the front axle support.

Release the bracket for the fuel lines from the oil pan.

Automatic transmission

Remove oil pipes from oil pan.

Release oil pan screws, gearbox and engine side.

Lower oil pan and remove from rear.

Scheme 139

If necessary, remove oil wiper.

Remove intake snorkel for oil pump if necessary.

The intake snorkel is secured with self-tapping screws. For this reason, no threading is present on new oil pans. Thread can be shaped using existing screws.

Replace seal for intake snorkel.

Sealing faces clean and free of seal debris.

Replace the oil pan seal.

Fill the openings in the oil pan seal above the joint for the end cover and the timing case with three Bond 1209.

Scheme 140

Insert all screws in oil pan.

Insert but do not yet tighten oil pan screws, gearbox side.

Tighten down screws on engine end.

Tighten screws on transmission end.

11 13 500 Removing and installing, sealing or replacing oil sump - engine removed (M44)

Drain engine oil.

Remove exhaust manifold.

Coat threads with copper paste.

Replace the seal and nuts.

Tightening torque, refer to 11 62 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Remove engine carrier.

Mount engine on assembly stand.

Scheme 141

Release guide tube for dipstick.

Scheme 142

Check/replace sealing ring.

Unscrew oil sump.

If necessary, remove oil wiper.

If necessary, remove intake snorkel for oil pump.

The intake snorkel is secured with self-tapping screws. For this reason, no threading is present on new oil sumps. Thread can be shaped using existing screws.

Replace seal for intake snorkel.

Sealing faces clean and free of seal debris.

Replace the oil sump gasket.

Fill openings in oil sump gasket through parting lines to sealing cover and to timing case with Drei Bond 1209.

To prevent any possibility of torsion stress when transmission is fitted, align oil sump on transmission end with engine block.

Scheme 143

11 14 100 Removing and installing, sealing or replacing timing case cover at top (M44)

Remove cylinder head cover, refer to 11 12 000.

Remove coolant thermostat, refer to 11 53 000.

Remove cylinder detection sensor from timing case cover.

Unfasten timing case cover.

Scheme 144

Remove rubber sealing strip.

Replace the rubber-profile seal.

Scheme 145

Cut seal at joints.

Scheme 146

Replace seal.

Note. Separate seals for the top gear case cover are available as spare parts.

Clean groove for rubber profile seal and sealing surfaces of remains of seal.

Apply Drei Bond 1209 at both the upper and lower sealing surfaces of the cylinder head.

Scheme 147

Install special tool 11 4 110.

Fit new seals.

Coat top and bottom of seals with Drei Bond 1209.

Scheme 148

Apply Drei Bond 1209 sealing compound thinly and evenly to the groove ends.

Seat new rubber seal in groove.

Scheme 149

Apply a thin coating of grease to top side of rubber profile gasket and both sides of special tool 11 2 330 and place special tool on gasket.

Scheme 150

Fit gear case cover. Insert screws and fit flush.

Carefully pull out special tool 11 2 330.

Scheme 151

Remove the sealing ring for the oil feed of the spray lead.

Check/replace sealing ring. Preassemble the sealing ring to the oil feed.

Install cylinder head cover without seal.

Install M 6 screws with large washers and press gear case cover down until upper edge of gear case cover and cylinder head are aligned.

Scheme 152

Tighten the screws.

Remove special tool 11 4 110, insert and tighten the remaining screws.

Tightening torque, refer to 11 14 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Scheme 153

11 14 110 Removing and installing, sealing or replacing timing case cover at bottom (M44)

Remove timing case cover at top, refer to 11 14 100 Removing and installing, sealing or replacing timing case cover at top (M44).

Remove vibration damper, refer to 11 23 010.

Release belt pulley.

Scheme 154

Release screws

Remove gear case cover, bottom.

Scheme 155

Note dowel sleeves (1).

Scheme 156

To fasten the seals, insert special tool 11 4 110.

Replace seal.

Coat the seal on the front and rear ends thinly with Drei Bond 1209.

Scheme 157

Install timing case cover, insert all screws and initially tighten to approx. 5 Nm.

Fully tighten all screws in alternate sequence.

Tightening torque, refer to 11 14 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Replace radial seal, refer to 11 14 141.

Removal and installation are described separately.

Remove timing chain, guide rail and tensioning rail, refer to 11 31 051.

Remove alternator.

Remove alternator carrier. Unscrew oil-filter cover

These tasks are described in Removing Main Flow Oil Filter . See 11 42 020.

Remove oil sump, refer to 11 13 000.

Release gear case.

Scheme 158

If necessary, remove oil pump and control valve, refer to 11 41 000.

If necessary, remove main flow oil filter, refer to 11 42 020.

If necessary, remove water pump, refer to 11 51 000.

Installation and removal are described separately.

Clean and remove grease from sealing surfaces of the engine block.

Ensure dowel sleeves (1) are correctly located.

Replace seal.

Coat the seal for the oil sump separating joint with Drei Bond 1209.

Scheme 159

Clean groove for rubber profile seal and sealing surfaces on gear case of remains of seal.

Apply Drei Bond 1209 sealing compound thinly and evenly to the groove ends.

Seat new rubber seal in groove.

Scheme 160

Apply a thin coating of grease to top side of rubber profile gasket and both sides of special tool 11 2 330.

Place special tool 11 2 330 on top side of rubber profile gasket.

Fit gear case.

Scheme 161

Install and tighten all screws.

Tightening torque, refer to 11 14 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Carefully pull out special tool 11 2 330.

Replace radial seal in timing case cover at bottom, refer to 11 14 141.

Assemble engine.

11 14 141 Replacing radial seal below timing case cover (M44)

Remove vibration damper, refer to 11 23 010

Fit Special Tool 11 2 313 on crankshaft.

Scheme 162

Screw in Special Tool 11 2 310 so far until it is rigidly connected with radial sealing ring.

Remove radial sealing ring by tightening in the screw.

Scheme 163

Coat sealing lips of new radial sealing ring with oil.

With Special Tool 11 4 150 and central screw, install radial sealing ring flush with timing-case cover.

Scheme 164

11 14 151 Replacing crankshaft radial seal (transmission side)

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

Necessary preliminary tasks

1. Remove gearbox
2. Drain off engine oil
3. Remove flywheel

Unfasten oil sump screws on transmission end.

Loosen oil pan.

Scheme 165

Release screws in end cover at rear.

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

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

Scheme 166

Note. As from 4/98, a new type of radial seal is used in the Series and as a replacement. This radial seal may only be supported with a "support bushing". If the radial seal is supported without the support bushing (1) for more than six months, operational reliability will no longer be assured and the radial seal must not be used any further.

Scheme 167

Distinguishing feature

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

Scheme 168

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

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

Scheme 169

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

Replace seal (2).

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

Scheme 170

Scheme 171

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

Lubricate contact face of crankshaft.

Scheme 172

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

Replace screws (1).

Insert all screws and tighten down end cover.

Scheme 173

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

Scheme 174

11 21 500 Replacing crankshaft (M44)

(Engine removed)

Remove lower timing case, refer to 11 14 115

Remove piston, refer to 11 25 530

Remove flywheel. See 11 22 500

Remove rear end cover, the procedure is described as part of replacing crankshaft radial sealing ring, refer to 11 14 151

Remove screws securing main bearing caps.

Remove main bearing cover 1 ... 5.

Lever out crankshaft.

Scheme 175

If necessary, unfasten increment gear.

Replace screws.

Install screws and tighten down in two passes.

Tightening torque, refer to 11 21 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Scheme 176

Scheme 177

Replacing main crankshaft bearing shells, refer to 11 21 531

Replacing conrod bearing shells, refer to 11 24 571

Replacing grooved ball bearing in crankshaft, refer to 11 21 571

11 21 531 Replacing all main crankshaft bearing shells (M44) (engine dismantled)

Note. Clean components before installing.

Note. Injection nozzles for cooling the pistons are installed on the underside of the cylinder between the bearing seats. In order to avoid the possibility of injury from the piston or connecting rod, the location of spray nozzles is equipped with special tool 11 7 320.

Scheme 178

Check the setting of the spray nozzles.

Attach special tool 11 7 320 to the intake side in the receiving bore hole in the engine block.

The spray nozzles must fit into the guide of special tool 11 7 320.

If necessary, loosen the spray nozzles and adjust and tighten them using special tool 11 7 320.

Tightening torque, refer to 11 11 7AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Scheme 179

Note. When crankshaft or main bearing shells are being replaced, the classification for the arrangement of the main bearing shells in the crankcase is no longer of significance. Install yellow main bearing shells in crankcase.

Scheme 180

Note. Guide bearing shell installed at bearing No. 4 is sole means of axial alignment for crankshaft.

Install guide bearing shell in crankcase.

Scheme 181

Install crankshaft.

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

Scheme 182

Note. Place main bearing shells with same color code as that of crankshaft in main bearing caps.

Scheme 183

Note. Main bearing caps 1 ... 3 bear identification markings on exhaust side.

The main bearing caps 4 and 5 are not marked.

Note that main bearing cap 4 has shoulders machined into end faces.

Scheme 184

Check main bearing clearance

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

Do not twist crankshaft.

Scheme 185

Place main bearing caps in position with grooves of all caps on same side. Align main bearing cap flush with side of bearing seat.

Note. To check main bearing clearance, use old main bearing screws. No oil is permitted in the blind bores (danger of cracking). Wash and oil screws.

Scheme 186

1. Tighten the main bearing bolts to joining torque.
2. Tighten down screws with special tool 11 2 110 or with special tool 00 9 120 with torsion angle.

Tightening torque, refer to 11 11 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Scheme 187

Remove main bearing cover and read off bearing clearance on width of squashed plastic thread using the measuring scale.

Main bearing clearance, refer to ENGINE - TECHNICAL DATA (M44)

Install new bearing shells with different color codes if necessary in order to check bearing clearance.

Scheme 188

Summary

Color code/shaft diameter/bearing strength

Ge = yellow

Gn = green

Ws = white

1. Crankshaft
2. Bearing clearance
3. Bearing shells: yellow, green or white
4. Bearing cover

Scheme 189

Remove plastic thread. Coat main bearing shells and crankshaft with engine oil. Place main bearing caps in position with grooves of all caps on same side. Align main bearing cap flush with side of bearing seat. Always replace main bearing screws with new ones. No oil is permitted in the blind bores (danger of cracking). Wash and oil screws.

1. Tighten the main bearing bolts to joining torque.
2. Tighten down screws with special tool 11 2 110 or with special tool 00 9 120 with torsion angle.

Tightening torque, refer to 11 11 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Check end float.

End float, refer to ENGINE - TECHNICAL DATA (M44)

If necessary, check the guide bearing shell, crankshaft and engine block.

Scheme 190

11 21 571 Replacing grooved ball bearings in crankshaft (M44)

(clutch removed)

Remove thrust bearing with Special Tool 11 2 340.

Scheme 191

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

Scheme 192

11 22 500 Removing and installing or replacing flywheel (M44)

(clutch removed)

Arrest flywheel with Special Tool 11 2 170.

Scheme 193

Unfasten screws and remove flywheel.

Scheme 194

Remember to fit hollow bush.

Scheme 195

The position of the dowel sleeve (1) in the dual-mass flywheel is marked with two notches beside the respective screw bore.

Scheme 196

Clean thread and install new micro-encapsulated screws.

Tightening torque, refer to 11 22 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

1. 11 2 150
2. 11 2 410 . See «ENGINE - SPECIAL TOOLS (M44)»(/bmw/z3/e36-1995-2000/remont/mechanical/#engine-special-tools-m44) .

If necessary, remove drive belt and belt pulley for the air-conditioning compressor.

Remove alternator drive belt.

Attach special tool 11 2 150 in conjunction with special tool 11 2 410.

When releasing and tightening down central bolt, grip special tool 11 2 150 with assistance of a second person.

If it is not possible to grip the tool securely: Remove mounted parts until the special tool 11 2 150 can be supported on the engine carrier without damaging other components.

Insert wood between engine carrier and special tool 11 2 150.

Scheme 197

Unscrew central bolt.

Replace radial seal in lower timing case cover.

Installation

Align vibration damper with groove to featherkey.

Replace central bolt.

Tightening torque see 11 23 5AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Scheme 198

11 24 571 Replacing all connecting-rod bearings (M44)

(piston removed)

Install new conrod bearing shells.

On each conrod, fit one red and one blue conrod bearing shell (regardless of colored mark on conrod shaft.

Scheme 199

Installing pistons, refer to 11 25 530

Check conrod bearing clearance.

Piston in BDC position.

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

Place bearing caps in position, making sure that matching numbers are paired.

Scheme 200

Use the old conrod bolts to check conrod clearance.

Tighten down conrod screws with special tool 00 9 120 or special tool 11 2 110.

Tightening torque, refer to 11 24 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Scheme 201

Remove bearing cover and read off bearing clearance across width of pinched plastic thread with the help of the measuring scale.

Conrod bearing clearance, refer to ENGINE - TECHNICAL DATA (M44)

Remove plastic thread.

Scheme 202

Summary

Color code/shaft diameter/bearing strength

Color code 2 classification.

Rt = red

Bl = blue

1. Crankpin
2. Bearing clearance
3. Bearing shells: red or blue
4. Conrod

Scheme 203

11 25 530 Removing and installing or replacing all pistons (M44)

(engine removed)

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

Remove cylinder head, refer to 11 12 100 Removing and installing cylinder head (M44) .

Remove oil pan, see 11 13 500

Scheme 204

Unscrew conrod bearing cover.

Scheme 205

Insert special tool 11 3 480 in conrod.

Remove conrod with piston from cylinder head side.

Scheme 206

Lift out retaining ring and press out piston pin.

Scheme 207

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

If necessary, replace connecting rods.

Spare connecting rods can only be obtained in complete sets.

It should be possible to press piston pin into bush by hand using only slight pressure. Clearance should then be minimal.

Scheme 208

Before installation, measure piston installation clearance.

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

Measuring point A, refer to ENGINE - TECHNICAL DATA (M44)

Scheme 209

Adjust micrometer on cylinder bore of engine block and set plug gauge on micrometer to zero. Measure bottom, center and top of cylinder bore in direction of travel and direction of engine rotation.

Diameter of the cylinder bore, refer to ENGINE - TECHNICAL DATA (M44)

Piston installation clearance, refer to ENGINE - TECHNICAL DATA (M44)

Max. permissible total wear clearance, refer to ENGINE - TECHNICAL DATA (M44)

Scheme 210

Install conrod bearing, refer to 11 24 571

Scheme 211

Install retaining ring.

Insert special tool 11 3 480 in conrod.

Lightly coat pistons and piston rings with oil.

Align contact points of piston rings (offset at approx. 120°, but not over piston pin lug).

Press together piston rings with special tool 11 2 260.

Scheme 212

Install pistons with arrows pointing towards camshaft drive.

The tightening strap must locate firmly right around circumference of engine block.

Scheme 213

Attach crankpin to connecting rod.

Scheme 214

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

Place bearing caps in position, making sure that matching numbers are paired.

Install new conrod bolts.

Scheme 215

Tighten down conrod bearing with special tool 00 9 120 or with special tool 11 2 110.

Tightening torque, refer to 11 24 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Check the setting of the spray nozzles.

Attach special tool 11 7 320 to the intake side in the receiving bore hole in the engine block.

Scheme 216

The spray nozzles must fit into the guide of special tool 11 7 320.

If necessary, loosen the spray nozzles and adjust and tighten them using special tool 11 7 320.

Tightening torque, refer to 11 11 7AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Assemble engine.

Scheme 217

11 25 671 Replacing piston rings on all pistons (M44)

(Piston removed)

Remove piston rings with a piston-ring compressing pliers.

Note. It might not be possible to find the identification on used piston rings. Put aside piston rings in correct sequence and installation position. New pistons may only be installed together with new piston rings.

Scheme 218

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

1. Plain compression ring
2. Stepped taper-face ring "TOP"
3. Disk ring with support spring

Arrange piston ring contact points with offset of approx. 120° to one another, but not over piston pin eye.

Scheme 219

Measuring end float, refer to ENGINE - TECHNICAL DATA (M44)

Scheme 220

Measuring contact clearance, refer to ENGINE - TECHNICAL DATA (M44)

Scheme 221

11 28 010 Replacing alternator drive belt (M44)

Note. If the drive belt are to be reused, mark the rotation direction and reinstall the drive belt with the same rotation direction.

Remove fan coupling with fan wheel, refer to 11 52 020

Remove the dust cab.

Push the tensioning device for the drive belt of the alternator back on the bolt connection of the pulley.

Remove drive belt.

Scheme 222

If necessary, apply preload to the tensioning device for the drive belt as far as possible and lock with Special Tool 11 3 340. This will make it easier to put on the drive belt.

Scheme 223

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

Put on the drive belt.

Push the tensioning device for the drive belt back on the pulley until Special Tool 11 3 340 is no longer under pressure; remove Special Tool 11 3 340.

Scheme 224

Layout of drive belt.

Make sure that drive belt is correctly seated in pulley grooves.

Scheme 225

11 28 020 Replace the tensioning device for the drive belt of the generator (M44)

Remove alternator drive belt. See 11 28 010

Remove the belt wheel of the vane pump.

Scheme 226

Loosen screws (1).

Loosen the screws (2) and remove with the tensioning device for the drive belt.

Note. If the screw (2) is inaccessable because of the lug (3), lock the tensioning device for the drive belt using Special Tool 11 3 340.

Scheme 227

If necessary, apply preload to the tensioning device for the drive belt on the pulley as far as possible and lock with Special Tool 11 3 340.

Unfasten screws (1 and 2).

Remove the tensioning device for the drive belt.

Scheme 228

11 31 001 Replacing camshaft (M44)

(intake or exhaust side as applicable)

Remove spark plugs.

Remove all fingers, refer to 11 33 050

Remove the gear-case cover, top, refer to 11 14 100 Removing and installing, sealing or replacing timing case cover at top (M44)

Remove the hydraulic chain tensioner, refer to 11 31 091

Removal of the camshaft is described separately from installation. Assembly sequence differs between removal and installation.

Turn central screw to rotate crankshaft in normal direction of rotation until piston of first cylinder is at firing TDC.

Note. At firing TDC, alignment bores are pointing upwards.

Remove dust cover from locating bore.

Secure crankshaft in TDC position with Special Tool 11 2 300.

Remove the chain wheels.

Scheme 229

Release the chain guide.

Scheme 230

Release the bearing cover and lay aside in correct order.

Lift out camshaft.

Scheme 231

Installation of the camshaft is described separately from removal. Assembly sequence differs between removal and installation.

Install camshaft.

Note. The camshafts are designated each with a cast letter. (A) for exhaust camshaft. (E) for intake camshaft.

Scheme 232

The designations of the bearing covers can be read on the intake side.

E1 ... E5 for the intake side.

A1 ... A5 for the exhaust side.

Fit the bearing cover and tighten down.

Tightening torque, refer to 11 31 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Install chain guide.

Position the camshafts using Special Tool 11 3 240 in firing TDC position of first cylinder.

Note. At firing TDC, alignment bores are pointing upwards.

Place the chain with the chain wheels.

Note. Arrow on chain wheel in cylinder axis points up.

Align long bores centrally.

Place the sensor gear onto the inlet chain wheel.

Note. Arrow on sensor gear in cylinder axis points up.

Insert all chain wheel screws and tighten so that they are free of play; the chain wheels remain loose.

Install hydraulic chain tensioner.

refer to 11 31 091

Tighten down the chain wheels.

Tightening torque, refer to 11 31 3AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Remove Special Tools 11 2 300 and 11 3 240.

Install all fingers, refer to 11 33 050

Assemble engine.

11 31 005 Checking timing of camshaft(s) (M44)

Remove fan coupling with fan wheel, refer to 11 52 020

Remove cylinder head cover, refer to 11 12 000

Remove spark plugs.

Turn central screw to rotate crankshaft in normal direction of rotation until piston of first cylinder is at firing TDC.

Remove dust cover from locating bore.

Secure crankshaft in TDC position with Special Tool 11 2 300.

Note. At firing TDC, alignment bores are pointing upwards.

Fit Special Tool 11 3 240 to camshaft.

Note. Special tool 11 3 240 must be flushly seated on the cylinder head.

Adjust camshaft timing if necessary, refer to 11 31 505

Removal and fitting are described separately.

Remove gear-case cover, top, refer to 11 14 100 Removing and installing, sealing or replacing timing case cover at top (M44)

Remove spark plugs.

Loosen the central bolt on the vibration damper, refer to 11 23 010

Rotate engine on loosened central screw engine wise until the first cylinder reaches its TDC firing position.

Note. The alignment bores of the camshafts in the firing TDC position point upwards.

Remove dust cover from locating bore.

Secure crankshaft in TDC position with Special Tool 11 2 300.

Position camshaft with Special Tool 11 3 240 in firing TDC position of first cylinder.

Note. Crankshaft and camshafts remain locked until assembly is complete.

Remove the loosened central bolt and take out the vibration damper.

Remove gear case cover, bottom, refer to 11 14 110

Remove the hydraulic chain tensioner, refer to 11 31 091

Remove the chain wheels.

Remove timing chain sprocket with timing chain from camshaft.

Scheme 233

If necessary, replace the slide and tensioning rails.

Release the slide and tensioning rails.

Scheme 234

Fitting and removal are described separately.

Install the slide and tensioning rails.

Turn the adjusting screw of the slide rail back approx. two revolutions.

Scheme 235

Fasten the slide rail to the cylinder head using screw (1).

Insert the screws and tighten them all except screw (1).

Remove screw (1).

Scheme 236

Place the adjusting screw of the slide rail free of play on the cylinder head.

Insert the screw (1) and tighten down the slide rail.

Scheme 237

Check the chain wheel and replace if necessary.

Align sprocket with woodruff key and install sprocket with timing chain in position.

Scheme 238

Check the chain wheels and replace if necessary.

Place the chain with the chain wheels.

Note. The arrows on the chain wheels in cylinder axis point up. Align long bores centrally.

Place the sensor gear onto the inlet chain wheel.

Note. Arrow on sensor gear in cylinder axis points up.

Insert all chain wheel screws and tighten so that they are free of play; the chain wheels remain loose.

Install hydraulic chain tensioner.

refer to 11 31 091

Tighten down the chain wheels.

Tightening torque, refer to 11 31 3AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Remove Special Tools 11 2 300 and 11 3 240.

If necessary, check the control diagram, refer to 11 31 005

Assemble engine.

11 31 091 Removing and installing or replacing chain tensioning device (M44)

Note. The hydraulic chain tensioner (M44) can also be fitted to the M42.

Unfasten screw plug and remove hydraulic chain tensioner.

Note. The hydraulic chain tensioner can also be removed if the timing-case cover is removed.

Scheme 239

If a hydraulic chain tensioner is reused, the oil chamber in the tensioner unit must first be drained.

Fasten the hydraulic chain tensioner into vice with protective vice jaws.

Scheme 240

Slowly and carefully push the hydraulic chain tensioner together, leaving the lock washer (2) still visible.

Repeat this procedure twice.

Scheme 241

Insert the hydraulic chain tensioner; replace the sealing ring of the drain plug.

Tighten the drain plug.

Tightening torque, refer to 11 31 7AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

11 31 501 Replacing camshaft - cylinder head removed (M44)

Preliminary work is described in section on dismantling and assembling the cylinder head, refer to 11 12 503

Remove all fingers, refer to 11 33 050

Release the chain guide.

Release the bearing cover and lay aside in correct order.

Lift out camshaft.

The camshafts are designated each with a cast letter.

(A) for exhaust camshaft.

(E) for intake camshaft.

Install camshaft.

The designations of the bearing covers can be read on the intake side.

E1 ... E5 for the intake side.

A1 ... A5 for the exhaust side.

Fit the bearing cover and tighten down.

Tightening torque, refer to 11 31 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Scheme 242

11 31 505 Adjusting timing of camshaft(s) (M44)

(re Oper. No. 11 31 005)

Note. Before performing the adjustment work, check timing of camshaft, refer to 11 31 005

Remove Special Tool 11 3 240 from cylinder head.

Remove Special Tool 11 2 300 from locating bore in engine block.

Rotate the engine on the central bolt engine wise until the camshafts on the fourth cylinder are located in the firing TDC position.

Loosen two screws on each chain wheel.

Scheme 243

Rotate the engine on the central bolt engine wise until the camshafts on the fourth cylinder are located in the firing TDC position.

Secure crankshaft in TDC position with Special Tool 11 2 300.

Loosen the remaining two screws on each chain wheel.

Scheme 244

Align the camshafts so that Special Tool 11 3 240 is flushly seated on the cylinder head.

Tighten two screws for each chain wheel.

For tightening torque, refer to 11 31 3AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Remove Special Tool 11 3 240 from cylinder head.

Scheme 245

Remove Special Tool 11 2 300 from locating bore in engine block.

Rotate the engine on the central bolt engine wise until the camshafts on the fourth cylinder are located in the firing TDC position.

Tighten the remaining two screws on each chain wheel.

Tightening torque, refer to 11 31 3AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Assemble engine.

11 33 050 Removing and installing/replacing all fingers (M44)

Remove cylinder head cover, refer to 11 12 000

Remove all spark plugs

Remove fan coupling with fan wheel, refer to 11 52 020

Rotate engine on central screw engine-wise until cams on camshaft point vertically upwards.

Note. The individual rocker may only be removed or installed if the camshaft is in this position.

Scheme 246

Press down valve with special tool 11 5 130 and lift out finger.

Note. Place fingers to one side in orderly fashion. Worn rockers may only be reused on the same grooves of the camshaft.

Scheme 247

Note. The rockers are crimped between the hydraulic valve clearance compensating element and the cam of the camshaft.

If necessary, replace camshaft, refer to 11 31 001

Scheme 248

11 33 062 Replacing all hydraulic valve clearance adjustment elements (HVA) (M44)

Remove all fingers, refer to 11 33 050

Pull out the hydraulic valve clearance adjustment elements (HVA).

Scheme 249

(cylinder head dismantled)

Machine valve seat face with Special Tool 00 3 520 or 00 3 580 with specifications of tool manufacturer.

Note. After machining the valve-seat face on OD and bore diameter, rework to specified diameter with correction milling tool until valve seat width (5) is obtained.

1. Valve-seat angle
2. Correction angle, outer
3. Correction angle, inner
4. Outside diameter of seat face
5. Valve-seat width

Pos. (1) to (5) refer to ENGINE - TECHNICAL DATA (M44)

(valve removed)

To measure tilt clearance, insert new valve so that valve stem end is flush with valve guide.

Mount dial gauge and measure tilt clearance.

Note. Maximum permitted tilt clearance

refer to ENGINE - TECHNICAL DATA (M44)

Note. If tilt clearance is excessive, the valve guide should be reamed and a repair valve with a larger shaft diameter

refer to ENGINE - TECHNICAL DATA (M44) , should be installed.

If necessary, ream out valve guide, refer to 11 12 600

(Valve removed)

Note. If clearance between valve shaft and valve guide is too large, ream out valve guide and install repair valve with larger shaft diameter.

Assemble reaming tool and guide taper (1) from special tool kit 00 4 210 depending on shaft diameter. Press guide taper (1) against valve seat and ream out valve guide (when dry) from combustion-chamber end. Rotate reaming tool once in downwards direction.

Note. After the reaming operation, rework the valve seat

refer to 11 12 527

Preliminary work is described in section on dismantling and assembling the cylinder head, refer to 11 12 503

Replacing valve stem seals, refer to 11 34 560

Remove valves from cylinder head.

If necessary, check valve guide for wear, refer to 11 12 595

If necessary, ream the valve guide, refer to 11 12 600

If necessary, rework valve seat, refer to 11 12 527

Installation sequence

1. Valve
2. Valve-stem seal
3. Lower plate spring
4. Valve spring
5. Upper plate spring
6. Valve tapers

Preliminary work is described in section on dismantling and assembling the cylinder head, refer to 11 12 503

Remove all valve springs, refer to 11 34 715

Remove valve stem seal with Special Tool 11 1 480.

Lubricate valve stem with oil and insert valve.

Fit Special Tool 11 1 960.

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

Press valve stem seal firmly home by hand with Special Tool 11 1 200.

Preliminary work is described in section on dismantling and assembling the cylinder head, refer to 11 12 503

Remove the camshafts, refer to 11 31 501

Insert Special Tool 11 1 441 from below in Special Tool 11 1 065 and secure with Special Tool 11 1 045.

Align Special Tool 11 0 345 in direction of valve shaft and select appropriate groove in Special Tool 11 0 342.

Press down valve spring on spring cap, top, and remove valve keys.

Remove valve spring and plate spring.

Installation sequence

1. Valve
2. Valve-stem seal
3. Lower plate spring
4. Valve spring
5. Upper plate spring
6. Valve tapers

Unscrew oil-filter cover

Note. Oil flows from oil-filter housing into oil pan.

Replace sealing ring.

Tightening Torque, refer to 11 42 2AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

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

Check/replace sealing rings on special tool 11 4 170.

Install special tool 11 4 170.

Tightening Torque, refer to 11 42 2AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Scheme 250

Connect special tools 13 3 061 / 063.

Start engine and check engine oil pressure, refer to ENGINE - TECHNICAL DATA (M44) .

Scheme 251

Loosen the oil filter cap using special tool 11 7 331.

Note. Oil flows from oil-filter housing into oil pan.

Tightening Torque, refer to 11 42 2AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Replace sealing rings.

Check seals on special tool 11 7 332 and replace if necessary.

Scheme 252

Instead of the oil filter cover, screw special tool 11 7 332 onto the oil filter housing and tighten using special tool 11 7 331.

Tightening Torque, refer to 11 42 2AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Connect special tools 13 3 061 / 063.

Start engine and check engine oil pressure, refer to ENGINE - TECHNICAL DATA (M44) .

Scheme 253

11 41 000 Removing and installing / replacing oil pump (M44)

Remove lower timing case, refer to 11 14 115

Release screws, remove oil-pump cover.

Lift out rotor set.

Note. Outer and inner rotor form a matched pair and must always be replaced as a set.

Scheme 254

Using a suitable drift, press spacer down until circlip is no longer under strain.

Remove circlip, remove control valve.

Scheme 255

Installation sequence

1. Control valve
2. Coil spring
3. Space bush
4. Circlip

Scheme 256

11 42 020 Removing and installing, sealing or replacing main-flow oil filter (M44)

Unfasten oil filter cover to allow oil to flow out of main flow oil filter housing and back into oil pan.

This operation is described in section on BMW engine oil service, refer to 00 00 249

Remove alternator

Unfasten vane pump for power steering unit from carrier (lines remain connected).

Remove alternator carrier.

Scheme 257

Remove full-flow oil-filter housing.

Scheme 258

Sealing faces clean and free of seal debris.

Replace seal.

Scheme 259

Replace the sealing rings on the non-return valve.

Check installed direction.

Scheme 260

11 51 000 Removing and installing / replacing water pump (M44)

Remove alternator drive belt, refer to 11 28 010

Release the belt pulley from the water pump.

Drain coolant.

Release water pump.

Scheme 261

Insert two M6 screws in water-pump thread and press out water pump evenly from gear case.

Scheme 262

Replace sealing ring.

Scheme 263

11 52 020 Removing and installing / replacing fan coupling (M44)

Lock belt pulley in position using Special Tool 11 5 050.

Release union nut with Special Tool 11 5 040 from water pump.

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

Scheme 264

Tightening torque, refer to 11 52 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44)

Note. Tightening torque 40 Nm when using Special Tool 11 5 040 is equivalent to 30 Nm on scale of a torque wrench.

Scheme 265

Unfasten screws and detach fan from fan coupling.

Scheme 266

11 53 000 Removing and installing / replacing coolant thermostat (M44)

Remove fan coupling with fan wheel, refer to 11 52 020

Drain coolant.

Release the coolant water lines.

Remove coolant thermostat housing.

Note. Coolant thermostat is integrated in coolant-thermostat housing and can only be replaced as a complete assembly.

Replace sealing ring.

Scheme 267

11 61 040 Removing and installing upper section of manifold (M44)

Remove Bowden cable for throttle actuation from throttle body.

Loosen the manifold support in front.

Remove the rubber gaiter from the throttle valve.

Remove connector for throttle potentiometer.

Pull off hose for tank ventilation.

Scheme 268

Disconnect adapter from brake booster.

Loosen the manifold support in back.

Release and remove collector upper housing.

Scheme 269

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

Replace the seals above and below the flange for the pressure regulating valve.

Scheme 270

11 61 044 Removing and installing lower section of manifold (M44)

Remove top section of manifold, refer to 11 61 040

Loosen guide pipe for dipstick.

Loosen the screws (1 and 2) and remove the manifold support.

Insert screws (1 and 2) and fit flush. Tighten the screws (1 and 2).

Scheme 271

Lower the coolant water level.

Disconnect preheating hose from flange for pressure regulating valve.

Scheme 272

Remove flange for pressure-control valve.

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

Replace the seals above and below the flange for the pressure regulating valve.

Separate the plug connections for the camshaft sensor and the crankshaft sensor at the cable duct.

Release the cable duct from the lower housing of the collector.

Separate the screw connections for the alternator and the starter.

Scheme 273

Unfasten lower section of manifold and remove from stud bolts until plug connections for oil pressure switch and temperature sensor for coolant are accessible.

Disconnect plug connections for oil pressure switch and temperature sensor for coolant.

Remove the lower housing of the collector.

Note. Bracket (1) for the plug connection of the knock sensors.

Scheme 274

Check for correct fit of hollow bushes (1).

Clean sealing faces.

Replace seal.

Scheme 275

11 62 000 Removing and installing, sealing / replacing exhaust manifold (M43 / M43TU / M44)

Remove exhaust system from exhaust manifold.

If necessary, remove air injection pipe.

Unfasten nuts and remove exhaust manifold.

Coat threads with CRC copper paste.

Replace gaskets and nuts.

Tightening Torque, refer to 11 62 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Scheme 276

11 78 510 Replacing Lambda oxygen sensor (as necessary, left or right) (M44)

Disconnect connector for oxygen sensor.

Unclip Lambda oxygen sensor cable from bracket.

Unfasten oxygen sensor.

Scheme 277

The threads of new oxygen sensors are already coated with Never Seez Compound.

If an oxygen sensor is used again, apply a thin and even coat of Never Seez Compound to the threads only.

Do not clean the Lambda oxygen sensor section which protrudes into the exhaust line and ensure that it avoids all contact with lubricants.

Tighten oxygen sensor with special tool 11 7 030.

Tightening Torque, refer to 11 78 1AZ in ENGINE - TORQUE SPECIFICATIONS (M44) .

Protect (mask) Lambda oxygen sensor when applying under seal.

Note cable routing of oxygen sensor.

Scheme 278

See also:
• ENGINE - TORQUE SPECIFICATIONS (M44)
• ENGINE - SPECIAL TOOLS (M44)
• ENGINE - TECHNICAL DATA (M44)
• 11 14 100 Removing and installing, sealing or replacing timing case cover at top (M44)
• 11 61 044
• 11 31 091
• 11 12 100
• 11 34 552
• 11 12 600
• 11 12 527
• 11 12 503
• 11 34 560
• 11 12 595
• 11 34 715
• 11 31 501
• 00 00 249
• 11 12 000.
• 11 53 000.
• 11 23 010.
• 11 14 141.
• 11 42 020.
• 11 13 000.
• 11 41 000.
• 11 51 000.
• 11 25 530
• 11 22 500
• 11 14 151
• 11 21 531
• 11 24 571
• 11 21 571
• 11 13 500
• 11 52 020
• 11 28 010
• 11 33 050
• 11 31 505
• 11 14 110
• 11 31 005
• 11 31 001
• 11 61 040