Engine - Repair (m54) BMW Z4 E85/E86

00 00 250 BMW engine oil service incl. supplementary service (M54)

Engine oil service

Release and tighten down main flow oil filter cap with a socket only.

When the main flow oil filter cap is opened, engine oil flows from the oil filter housing back into the oil sump.

Release main flow oil filter cap and remove towards top.

Installation

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

Scheme 1

Installation

Replace and oil O-ring.

Scheme 2

Drain or draw off engine oil.

When engine oil is drained, open cap in engine underguard.

Open oil drain plug and drain off engine oil.

Installation

Replace sealing ring.

Tightening torque, see 11 13 1AZ ENGINE - TIGHTENING TORQUES .

Scheme 3

Complete vehicle and set in horizontal position.

Top up engine oil.

Start engine and run at idle until oil indicator lamp goes out.

Switch off engine, wait approx. 5 minutes and then check engine oil level.

Top up engine oil if necessary.

11 00 039 Checking compression of all cylinders (M60 / M62 / M73 / S62 / M54)

Special tools required

1. 11 0 224
2. 11 0 226

Necessary preliminary tasks

1. Connect charger or a second battery.
2. Read out fault memory of DME control unit
3. Pull fuel pump relay or fuel pump fuse.
4. Start engine and allow residual fuel to drain out (pressure reduction).
5. Remove all spark plugs. See «12 12 011 REPLACING ALL SPARK PLUGS»(/bmw/z4/e85e86-2002-2005/remont/gauges-instrument-panels/#engine-electrical-system-repair__12-12-011-replacing-all-spark) .

Screw special tool 11 0 226 by hand into spark plug thread and connect special tool 11 0 224.

Note. Check that sealing ring is in perfect condition.

Scheme 4

Depress accelerator and actuate starter until compression stops rising.

Compression pressure.

Scheme 5

Assemble engine.

Now clear the fault memory.

11 00 045 Checking absolute compression of all cylinders

With BMW Diagnosis Information System (DIS).

Scheme 6

1. Connect DIS tester
2. BMW measuring technology
3. Preset measurements
4. Absolute compression
5. Clear fault memory

11 00 050 Removing and installing engine (M54)

Special tools required

1. 11 0 020
2. 51 2 170

Disconnect negative battery lead.

Exhaust manifold 1-3 remains on engine during removal.

Observe specified tightening torque and safety precautions in all work steps.

Move engine hood into assembly position with special tool 51 2 170.

REMOVING AND INSTALLING ENGINE

Remove electronics box cover.

Unlock and detach plug connections (1 and 2).

Release nut and remove grounding cable.

Pull relay carrier (3) completely up and out of electronics box.

Scheme 7

REMOVING AND INSTALLING ENGINE

Installation

Observe specified tightening torque and safety precautions in all work steps.

11 12 000 Removing and installing, sealing cylinder head cover (M52TU / M54 / M56)

Remove engine cover.

Remove 12 13 511 IGNITION COILS (M54) .

Remove wiring harness of ignition coils from cylinder head cover and place to one side.

Note. Illustrations are from an M54 engine.

Press lock.

Pull off the hose for the engine breather.

Scheme 8

Remove grounding straps (1).

Remove cylinder head cover.

Scheme 9

Installation

Remove sealing debris from sealing faces of cylinder head and cylinder head cover.

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

Scheme 10

Installation

Apply a thin and even sealing bead of Drei Bond at transition to half-moon sections at VANOS adjustment unit.

Scheme 11

Note. Illustration with engine removed.

Installation

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

Check seals and replace if necessary.

Scheme 12

Note. Illustration with engine removed.

Installation

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

Install cover bolts and align cylinder head cover.

Hand-tighten all cover bolts without preload. Tighten cap nuts crosswise from inside to outside.

Scheme 13

11 12 100 Removing and installing/replacing cylinder head (M52TU / M54 / M56)

Special tools required

1. 00 0 200
2. 00 9 120

Remove both exhaust manifolds . See Exhaust Manifold .

Note. After removing exhaust manifolds

Reinstall engine support arm with engine mount and remove special tool 00 0 200.

Remove intake filter housing with air-mass flow sensor.

Remove cylinder head cover . See Cylinder Head With Cover .

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

Remove intake air manifold . See 11 61 050 Removing And Installing Intake Air Manifold (M54) .

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

Installation

Replace sealing ring on drain plug.

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

Vent cooling system and check for leaks . See 17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR LEAKS .

Remove coolant thermostat housing. . See Coolant Thermostat .

Remove coolant pipe.

Note. If the coolant pipe cannot be fed out

Release banjo bolt (1) and disconnect oil pressure line for VANOS adjustment unit.

Scheme 14

Installation

Replace O-ring on coolant pipe.

If necessary, replace sealing rings on banjo bolt (1).

Tightening torque of banjo bolt (1), see 11 36 2AZ in ENGINE - TIGHTENING TORQUES

Removal

Removal of cylinder head is described separately from installation.

Remove double VANOS adjustment unit . See 11 36 010 Removing And Installing Or Replacing Double VANOS Adjustment Unit (M52TU / M54 / M56) .

Remove camshafts with bearing strips . See 11 31 001 Replacing Camshaft (M52TU / M54 / M56) .

Release screw connection between timing case cover and cylinder head.

Scheme 15

Release screws, remove chain guide.

Scheme 16

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

Lift off cylinder head.

Scheme 17

Installation

Installation of cylinder head is described separately from removal.

Clean sealing faces of cylinder head and engine block; if necessary, remove traces of gasket with hardwood spatula.

Make sure no gasket remnants drop into oil and cooling channels.

Check adapter sleeves for damage and correct installation position.

Apply permanently elastic sealing compound Drei Bond 1209 to joints to timing case cover.

Replace cylinder head gasket.

Scheme 18

Note. A cylinder head seal 0.3 mm thicker than usual can be obtained for machined (milled) cylinder heads.

Scheme 19

Use cylinder head bolts only once.

There must be no oil in the tapped holes of the engine block and the timing case cover.

Risk of cracking and distorted tightening values.

Put the cylinder head on.

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

Tighten down cylinder head bolts in sequence 1 to 14.

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

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

Scheme 20

Install chain guide.

Scheme 21

Insert screws and tighten down screw connection between timing case cover and cylinder head.

Install camshafts . See 11 31 001 Replacing Camshaft (M52TU / M54 / M56) .

Install double VANOS adjustment unit . See 11 36 010 Removing And Installing Or Replacing Double VANOS Adjustment Unit (M52TU / M54 / M56) .

Assemble engine.

Scheme 22

11 12 101 Replacing cylinder head gasket (M52 / S52 / M52TU / M54 / M56)

Tasks are identical to Removing and installing cylinder head . See Cylinder Head With Cover .

11 12 503 Disassembling and assembling cylinder head (M52 / S52 / M52TU / M54 / M56)

Special tools required

1. 00 1 490
2. 11 0 192
3. 11 0 342
4. 11 0 343
5. 11 0 345
6. 11 1 045
7. 11 1 065
8. 11 1 067
9. 11 1 071
10. 11 1 441
11. 11 1 442

(cylinder head removed)

If necessary, remove coolant thermostat. See Coolant Thermostat .

Screw on special tool 11 1 442.

Scheme 23

Screw special tool 11 1 065 onto special tool 00 1 490.

Provide special tools for disassembling cylinder head

Scheme 24

1. special tool 11 1 071
2. special tool 11 1 067
3. special tool 11 0 192
4. special tool 11 1 045
5. special tool 11 0 342
6. special tool 11 0 343
7. special tool 11 0 345
8. special tool 11 1 441

Assemble special tools.

Scheme 25

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

Scheme 26

Place cylinder head on special tool 11 1 065 and screw on with two screws.

Scheme 27

Remove all valve springs . See 11 34 715 Replacing All Valve Springs (M52 / S52 / M52TU / M54 / M56) .

Remove all valve stem seals . See 11 34 560 Replacing All Valve Stem Seals (M52 / S52 / M52TU / M54 / M56) .

Remove all valves . See 11 34 552 Removing And Installing Or Replacing All Valves (M52 / S52 / M52TU / M54 / M56) .

11 12 527 Remachining a valve seat (M52 / S52 / M52TU / M54 / M56)

Special tools required

1. 00 3 520
2. 00 3 580

(cylinder head dismantled)

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

Scheme 28

Note. After machining the valve seat surface, remachine the outside and inside diameters with a correction milling tool to the prespecified diameter to produce valve seat width (5).

1. Valve-seat angle
2. Correction angle, outside
3. Correction angle, inside
4. Outside diameter seat face
5. Valve-seat width

Specified values (1 to 5). (Scheme 29)

Scheme 29

11 12 595 Checking a valve guide for wear (M52 / S52 / M52TU / M54 / M56)

(valve removed)

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

Attach dial gauge and measure tilt clearance.

Note. Max. permissible tilt clearance.

Scheme 30

Note. If tilt clearance is excessive, valve guide is reamed out and a repair valve with a larger shaft diameter is installed.

If necessary, ream valve guide . See 11 12 600 Reaming A Valve Guide (M52 / S52 / M52TU / M54 / M56) .

Scheme 31

11 12 600 Reaming a valve guide (M52 / S52 / M52TU / M54 / M56)

Special tools required

1. 00 4 210

(valve removed)

Note. In event of excessive clearance between valve stem and valve guide: Valve guide is reamed and a repair valve with a larger stem diameter is installed.

Assemble reaming tool and guide taper (1) from special tool kit 00 4 210 depending on stem diameter. Press guide taper (1) onto valve seat. Starting from combustion chamber side, ream valve guide dry. Rotate reaming tool once in downwards direction.

Note. Remachine valve seat after reaming.

Scheme 32

11 12 719 Resurfacing cylinder head sealing surface (M52 / M52TU / M54 / M56)

(cylinder head dismantled)

Check flatness of cylinder head sealing surface with a commercially available straightedge.

Deviation from flatness max. 0.05 mm.

Scheme 33

Note. Machining limit.

Scheme 34

Note. For compression comparison check, a repair cylinder head seal is provided.

Scheme 35

11 12 729 Checking cylinder head for watertightness (M52TU / M54 / M56)

Special tools required

1. 11 7 390
2. 11 7 391
3. 11 7 392
4. 11 7 393
5. 11 7 394
6. 11 7 395
7. 11 7 396
8. 11 7 397
9. 11 7 398

(cylinder head dismantled)

Prepare special tool kit 11 7 390.

Note. Special tool kit 11 7 390 consists of special tools 11 7 391 / 11 7 392 / 11 7 393 / 11 7 394 / 11 7 395 / 11 7 396 / 11 7 397 / 11 7 398.

Place special tools 11 7 391 / 11 7 392 on cylinder head sealing surface and screw down with cylinder head bolts.

Scheme 36

Turn back screw (1).

Note. special tool 11 7 394 is secured with a pin (2).

Fit special tool 11 7 394.

Scheme 37

Insert screw (1) by hand until special tool 11 7 393 rests on sealing surface.

Tighten down screw (1) by approx. a half to one turn.

Scheme 38

Check sealing rings (1) and coat with water as anti-friction coating. Insert special tool 11 7 395 and tighten down.

Scheme 39

Seal coolant apertures with special tool kit 11 7 390.

Scheme 40

Connect compressed air to special tool 11 7 395.

Immerse cylinder head in a water bath. Inspection pressure 4.5 bar.

Check cylinder head for escaping air (cracks).

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

Scheme 41

11 13 000 Removing and installing, sealing or replacing oil sump (M52TU / M54 / M56)

Special tools required

1. 00 0 200
2. 00 0 201
3. 00 0 202
4. 00 0 204
5. 00 0 208

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

Assemble special tool 00 0 200 with special tools 00 0 201 / 00 0 202 / 00 0 204 / 00 0 208 and fit.

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

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

Scheme 42

Tighten the screws (1 and 2).

Scheme 43

Raise engine with special tool 00 0 200 approx. 5 mm.

Scheme 44

Remove suction filter housing .

Remove engine splash guard.

Drain engine oil .

On vehicles with automatic transmission

Disconnect oil lines from automatic transmission and from oil pan.

Release guide tube for dipstick.

Note. M52 TU and M54 only.

Detach return hose from cyclone oil separator on oil dipstick guide tube.

Remove oil dipstick guide tube upwards.

Scheme 45

Installation

Replace O-ring.

Scheme 46

Remove front end reinforcement.

Detach steering spindle from steering gear . See STEERING GEAR .

Remove vane pump for power steering unit (lines remain connected).

Disconnect plug connection to oil level sensor.

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

Scheme 47

11 13 000 Removing and installing, sealing or replacing oil sump (M54)

Necessary preliminary tasks

1. Remove intake filter housing.
2. Remove guide tube for oil dipstick. (Scheme 45)
3. Lowering front axle support.
4. Drain off engine oil.
5. Disconnect plug connection to oil level sensor.

On vehicles with automatic transmission

Detach oil lines from automatic transmission and from oil pan.

Unfasten oil pan screws at transmission and engine ends.

Lower and remove oil pan.

Scheme 48

Installation

Sealing faces clean and free of seal debris.

Apply approx. 3 mm wide, 2 mm high coat of Drei Bond to the area around seams.

Scheme 49

Installation

1. Replace seal.
2. Install oil sump.
3. Insert all screws on transmission end
4. without preload at this stage.
5. Tighten down screws on engine end.
6. Tighten screws on transmission end.

11 14 110 Removing and installing lower timing case cover (M52 / S52 / M52TU / M54)

Remove VANOS adjustment unit . See 11 36 010 Removing And Installing Or Replacing Double VANOS Adjustment Unit (M52TU / M54 / M56) .

Remove coolant thermostat . See Coolant Thermostat .

Remove alternator drive belt and drive belt tensioner.

Brace pulley for water pump with drive belt and unfasten screws.

Scheme 50

M52 / S52 only

Unfasten engine speed sensor.

Scheme 51

Remove vibration damper . See 11 23 010 Removing And Installing Or Replacing Vibration Damper (M52TU / M54 / M56) .

Version where vibration damper and hub are two parts: Remove hub for vibration damper . See 11 23 010 Removing And Installing Or Replacing Vibration Damper (M52TU / M54 / M56)

Remove oil sump . See 11 13 000 Removing And Installing, Sealing Or Replacing Oil Sump (M52TU / M54 / M56) .

Drive out dowel pins from timing case cover towards rear.

(Mandrel diameter less than 5 mm)

Scheme 52

Unscrew timing case cover to cylinder head bolts.

Scheme 53

Unfasten screws and remove timing case cover.

Scheme 54

Installation

Clean sealing surfaces.

Drive alignment pins into timing case cover until they protrude approx. 2 to 3 mm.

Scheme 55

Installation

Secure new seals to timing case cover with a little grease.

Scheme 56

Installation

Sealing faces clean and free of seal debris.

Apply Drei Bond 1209 sealing compound at following points

1. A bead at the transitions to the cylinder head gasket on the left and right.
2. Thinly and evenly to the entire sealing face of the timing case cover to the cylinder head gasket.

Scheme 57

Installation

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

Scheme 58

Installation

Drive in dowel pins from front until flush.

Scheme 59

Installation

Fully tighten all screws in alternate sequence.

Tightening torque, see 11 14 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 60

Insert screws, tighten screw connection for timing case cover to cylinder head.

Scheme 61

Replace radial seal in lower timing case cover . See 11 14 141 Replacing Radial Seal In Lower Timing Case Cover .

Assemble engine.

11 14 141 Replacing radial seal in lower timing case cover

Special tools required

1. 11 2 380
2. 11 2 383
3. 11 2 385
4. 11 3 280

Note. This repair instruction is valid for the following engines: M50 / M52 / M52TU / M54 / M56 S52

Remove vibration damper . See 11 23 010 Removing And Installing Or Replacing Vibration Damper (M52TU / M54 / M56) .

Note. Version where vibration damper and hub are two parts

Remove hub for vibration damper . See 11 23 010 Removing And Installing Or Replacing Vibration Damper (M52TU / M54 / M56) .

Fit special tool 11 2 383 to crankshaft.

Scheme 62

Fit special tool 11 2 385 to crankshaft.

Align groove of special tool 11 2 385 to featherkey of crankshaft.

Note. Special tool 11 2 385 centers special tool 11 2 380.

Scheme 63

Screw in special tool 11 2 380 until it has made firm contact with radial seal.

Remove radial seal by tightening screw on special tool.

Scheme 64

Installation

Coat sealing lips of new radial sealing ring with oil.

Using special tool 11 3 280 and centering screw, install new radial seal flush with timing case cover.

Scheme 65

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 66

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 67

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 68

Distinguishing feature

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

Scheme 69

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 70

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 71

Scheme 72

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 73

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

Replace screws (1).

Insert all screws and tighten down end cover.

Scheme 74

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 75

11 21 500 Replacing crankshaft (M52 / S52 / M52TU / M54 / M56)

(engine removed)

Necessary preliminary tasks

1. Removing cylinder head
2. Removing lower timing case cover
3. Removing all pistons
4. Remove end cover at rear; this operation is described in the section Replacing crankshaft radial seal .

Checking axial clearance

If permitted end float is exceeded, check crankshaft, guide bearing shells and engine block, replacing if necessary, end float .

Scheme 76

Unfasten screw connection on reinforcement plates.

Note. The reinforcement plates are not fitted on engines with gray cast iron engine blocks or on engines with oil pumps integrated in oil scrapers.

Scheme 77

Unfasten screw connection on main bearing.

Remove main bearing caps (1 to 7).

Lever out crankshaft.

Scheme 78

If necessary, release incremental gear.

Installation

Replace screws.

Install screws and tighten down in two passes.

Tightening torque, see 11 21 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 79

Replace main crankshaft bearing shells . See . 11 21 531 Replacing All Main Crankshaft Bearing Shells (M52 / S52 / M52TU / M54 / M56)

Replace conrod bearing shells . See 11 24 571 Replacing all connecting rod bearings (M52 / S52 / M52TU / M54 / M56) .

Replace grooved ball bearings in crankshaft . See 11 21 571 Replacing Grooved Ball Bearing In Crankshaft (M52 / S52 / M52TU / M54 / S50 / S54) .

11 21 531 Replacing all main crankshaft bearing shells (M52 / S52 / M52TU / M54 / M56)

Special tools required

1. 00 2 590
2. 00 9 120
3. 11 2 110

(engine dismantled)

M52 B20 / M52TU B20 M54 M22

Note. Injection nozzles for cooling the pistons are installed in the bores of bearing seats 2 to 7.

Scheme 80

M52 B25 / B28

S52 M52TU B25 / B28

M54 B25 / B30

M56

Note. Injection nozzles for cooling the pistons are installed on the underside of the cylinder between the bearing seats.

Installation

Screw threads are coated with screw securing adhesive (Loctite).

Replace screws.

Scheme 81

Scheme 82

Installation

When replacing the bearing shells (also for replacement crankshaft), classification for bearing shell arrangement in engine block is waived.

Insert bearing shells with yellow color coding in engine block.

Scheme 83

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

Scheme 84

Note. The axial guide on the crankshaft is fitted to bearing point 6. Insert pilot bearing shell in the engine block.

Scheme 85

Install crankshaft.

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

Scheme 86

Installation

The bearing shell classification for the bearing cover is marked on the crankshaft in yellow, green or white paint.

Insert main bearing shells with same crankshaft color coding in main bearing caps.

Scheme 87

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

1. Bearing shell
2. Guide bearing

Observe grinding stage of main bearing journals. (Scheme 79)

Scheme 88

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

Scheme 89

Check clearance on main crankshaft bearing.

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

Do not twist crankshaft.

Scheme 90

Install main bearing cap so that grooves in main bearing shell guide are one side.

Align main bearing cap flush with side of bearing seat.

Scheme 91

Installation

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

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

1. Tighten down main bearing screws with jointing torque.
2. Tighten down main bearing bolts with special tool 00 9 120 to angle of rotation.

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

Scheme 92

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

Radial crankshaft bearing clearance .

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

Scheme 93

Remove plastic thread.

Coat main bearing shells and crankshaft with engine oil.

Install main bearing cap so that grooves in main bearing shell guide are one side.

Align main bearing cap flush with side of bearing seat.

Scheme 94

Installation

Always replace bolts of main bearing cap with new bolts.

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

Note. The reinforcement plates are not fitted on engines with gray cast iron engine blocks or on engines with oil pumps integrated in oil scrapers.

Installation

Install reinforcement plates and fit screws with zero backlash.

Install main bearing shells and abut firmly.

Tighten down screw connection on reinforcement plates.

Scheme 95

Tightening specifications for main bearing

Scheme 96

1. Tighten all screws on main bearing cover with jointing torque.
2. Unfasten screws on main bearing cover 6.
3. Strike back and front of crankshaft with plastic hammer to center thrust bearing (do not damage crankshaft).
4. Tighten screws of main bearing cover 6 with jointing torque.
5. Tighten down all screws of main bearing caps with special tool 11 2 110 or with special tool 00 9 120 to torsion angle. Tightening torque, see 11 11 1AZ in «ENGINE - TIGHTENING TORQUES»(/bmw/z4/e85e86-2002-2005/remont/mechanical/#engine-tightening-torques) .

Check axial play.

If permitted end float is exceeded, check crankshaft, guide bearing shells and engine block, replacing if necessary, end float .

Scheme 97

11 21 571 Replacing grooved ball bearing in crankshaft (M52 / S52 / M52TU / M54 / S50 / S54)

Special tools required

1. 00 5 500
2. 11 2 340
3. 11 2 350

(clutch removed)

Scheme 98

Version with grooved ball bearing

Remove guide bearing with special tool 11 2 340.

Scheme 99

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

Scheme 100

11 22 500 Removing and installing or replacing flywheel (M52 / S52 / M52TU / M54 / S54)

Special tools required

1. 11 2 170

(clutch removed)

Lock flywheel with special tool 11 2 170.

Scheme 101

Unfasten screws and remove flywheel.

Scheme 102

Installation

Check dowel sleeve for damage and correct installation position.

Scheme 103

Installation

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

Scheme 104

Installation

Clean thread and install new micro-encapsulated screws.

Tightening torque, see 11 22 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 105

11 22 513 Replacing roller bearing for dual-mass flywheel

Special tools required

1. 21 2 051
2. 21 2 052

Note. Flywheel removed!

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

Scheme 106

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 107

11 23 010 Removing and installing or replacing vibration damper (M52TU / M54 / M56)

Special tools required

1. 11 8 190
2. 11 8 200
3. 11 8 210

Necessary preliminary tasks

1. Unscrew and remove splash guard.
2. E83/E85/E60: Remove fan cowl with electric fan . See «FAN COWL»(/bmw/z4/e85e86-2002-2005/remont/cooling-fan/#cooling-fans__fan-cowl) .
3. Remove A/C compressor drive belt . See «A/C COMPRESSOR DRIVE BELT»(/bmw/z4/e85e86-2002-2005/remont/charging-system/#generators-regulators__ac-compressor-drive-belt) .
4. Remove alternator drive belt . See «GENERATOR DRIVE BELT»(/bmw/z4/e85e86-2002-2005/remont/charging-system/#generators-regulators__generator-drive-belt) .

Version 1

Vibration damper and hub for vibration damper are two parts

Unscrew vibration damper bolts and take off vibration damper.

Scheme 108

Version 1

Vibration damper and hub for vibration damper are two parts

Installation

Align locating bore in vibration damper to dowel pin.

Install and tighten down screws.

Tightening torque, see 11 23 3AZ in ENGINE - TIGHTENING TORQUES .

Scheme 109

Version 2

Vibration damper and hub for vibration damper are one part

Screw special tool 11 8 190 to special tool 11 8 200.

Scheme 110

Version 2

Note. Special tool 11 8 200 must snap into place in openings (1).

Scheme 111

Version 2

When releasing and tightening down central bolt, grip special tool 11 8 190 with assistance of a second person.

Version 2

Insert special tool 11 8 200 in openings on vibration damper and turn counterclockwise so that counter-supports snap into place on vibration damper.

Release central screw (1).

Scheme 112

Version 2

Feed out special tools 11 8 190 / 11 8 200.

Remove central screw and washer.

Carefully detach vibration damper (1) by hand.

Scheme 113

Version 2

Note. If vibration damper cannot be detach by hand

Insert special tool 11 8 200 in openings on vibration damper and turn clockwise so that counter-supports snap into place on vibration damper.

Scheme 114

Version 2

Screw out spindle (1) on special tool 11 8 210 as far as possible.

Z3 only

Screw in spindle (1) on special tool 11 8 210 approx. 15 mm and screw out again only after installation between special tool 11 8 200 and cooler.

Scheme 115

Version 2

Screw special tool 11 8 210 to special tool 11 8 200.

Detach vibration damper by turning spindle (1) on special tool 11 8 210.

Scheme 116

Version 2

Installation

Check featherkey (1) for damage and correct installation position.

Replace radial seal in lower timing case cover . See 11 14 141 Replacing Radial Seal In Lower Timing Case Cover .

Scheme 117

Version 2

Installation

Align groove (1) in vibration damper to featherkey.

Fit vibration damper.

Scheme 118

Version 2

Installation

Replace central screw (1).

Install central screw and washer.

Scheme 119

Version 2

Installation

Screw special tool 11 8 190 to special tool 11 8 200.

Scheme 120

Version 2

Insert special tool 11 8 200 in openings on vibration damper and turn clockwise so that counter-supports snap into place on vibration damper.

Tighten down central screw (1).

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

Scheme 121

11 24 571 Replacing all connecting rod bearings (M52 / S52 / M52TU / M54 / M56)

Special tools required

1. 00 2 590
2. 00 9 120
3. 11 2 110

(piston removed)

Install new conrod bearing shells.

Insert one blue (1) and one red (2) bearing shell (irrespective of the color coding on the conrod shaft).

Scheme 122

Install piston . See 11 25 530 Removing And Installing Or Replacing All Pistons (M52 / S52 / M52TU / M54 / M56) .

Check conrod bearing clearance.

Piston in BDC position.

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

Fit bearing caps so that pair numbers match up.

Scheme 123

Use the old conrod bolts to check conrod clearance.

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

Tightening torque, see 11 24 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 124

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. Coat crankshaft and bearing shells with oil.
3. Install new conrod bolts and tighten down.

Tightening torque, see 11 24 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 125

11 25 530 Removing and installing or replacing all pistons (M52 / S52 / M52TU / M54 / M56)

Special tools required

1. 00 9 120
2. 11 2 110
3. 11 2 260
4. 11 2 470
5. 11 3 480
6. 11 8 141

(engine removed)

Remove cylinder head.

Removal

Removal of pistons is described separately from installation.

Assembly sequence for removal and installation is different.

Remove oil pump . See 11 41 000 Removing And Installing/Replacing Oil Pump (M52TU / M54 / M56) .

If oil pump and oil scraper are two parts

Remove oil scraper.

Scheme 126

Note. Figure shows crankshaft removed.

On engines with spray nozzles for piston cooling on cylinder underside

Scheme 127

Installation

Screw threads are coated with screw securing adhesive (Loctite). Replace screws.

In event of heavy oil carbon residue

Carefully remove oil carbon residue from cylinder wall.

Scheme 128

Unscrew conrod bearing cover.

Scheme 129

Insert special tool 11 3 480 in conrod.

Remove conrod with piston from cylinder head side.

Scheme 130

Lift out retaining ring and press out piston pin.

Scheme 131

Installation

Installation of pistons is described separately from removal. The assembly sequence differs between removal and installation.

The piston pin must be able to be pressed through the liner by hand with little force and must not display any significant play.

Scheme 132

Measure piston installation clearance

Measure piston diameter with micrometer at distance A from the underside of the piston and at offset angle of 90° to piston pin axis.

Measurement A .

Scheme 133

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

Diameter of cylinder bore .

Piston installation clearance .

Total permissible wear tolerance .

Scheme 134

Replace conrod bearing shells . See 11 24 571 Replacing All Connecting Rod Bearings (M52 / S52 / M52TU / M54 / M56) .

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

Scheme 135

Install snap ring so that opening is opposite recess.

Scheme 136

Insert special tool 11 2 470 in conrod.

Scheme 137

Lightly coat pistons and piston rings with oil.

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

Note. Piston diameter 84 mm: Use special tool 11 8 141. Piston diameter 80 mm: Press together piston rings with special tool 11 2 260.

Scheme 138

Install piston so that arrow points to camshaft drive.

Entire circumference of tightening strap must rest firmly on engine block.

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

Scheme 139

Attach crankpin to connecting rod.

Scheme 140

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

Fit bearing caps so that pair numbers match up.

Install new conrod bolts.

Scheme 141

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

Tightening torque, see 11 24 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 142

Install oil pump . See 11 41 000 Removing And Installing/Replacing Oil Pump (M52TU / M54 / M56) .

If oil pump and oil scraper are two parts

Fit oil scraper.

Assemble engine.

Scheme 143

11 25 671 Replacing piston rings on all pistons (M52 / S52 / M52TU / M54 / M56)

(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.

Only install new pistons in conjunction with new piston rings.

Scheme 144

Installation

Install piston rings with "TOP" to piston top.

Scheme 145

1. Plain compression ring
2. Stepped compression ring "Top"
3. Slotted oil ring with hose spring clip

Measure axial play .

Scheme 146

Measure end clearance .

Scheme 147

11 28 010 Replacing alternator drive belt (M52 / S52 / M52TU / M54 / M56)

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

Necessary preliminary tasks

1. Remove A/C compressor drive belt See «11 28 050 Replacing A/C Compressor Drive Belt (M52 / S52 / M52TU / M54 / M56)»(/bmw/z4/e85e86-2002-2005/remont/mechanical/#engine-repair-m54__11-28-050-replacing-ac-compressor) .
2. E85/E60: Remove radiator cover See «RADIATOR COVER»(/bmw/z4/e85e86-2002-2005/remont/cooling-fan/#cooling-fans__radiator-cover) .
3. E85/E60: Remove fan cowl See «FAN COWL»(/bmw/z4/e85e86-2002-2005/remont/cooling-fan/#cooling-fans__fan-cowl) .

Remove cap from tensioning roller.

Scheme 148

Relieve tension on belt drive.

Remove drive belt.

Installation

Check drive belt for coolant and oil residues, replace if necessary.

Scheme 149

Installation

Check that belt is correctly positioned on belt pulleys.

Scheme 150

Version with auxiliary tensioning roller.

Scheme 151

Installation

Locking device of auxiliary tensioning roller must snap into groove on alternator.

Scheme 152

Version on E85.

Scheme 153

Version on E60/E65.

Scheme 154

11 28 020 Replacing alternator drive belt tensioner (M52 / S52 / M52TU / M54)

Necessary preliminary tasks

1. Remove alternator drive belt . See «11 28 010 Replacing Alternator Drive Belt (M52 / S52 / M52TU / M54 / M56)»(/bmw/z4/e85e86-2002-2005/remont/mechanical/#engine-repair-m54__11-28-010-replacing-alternator-drive) .

Note. Version with auxiliary tensioning roller: Remove auxiliary tensioning roller.

Installation

Locking device of auxiliary tensioning roller must snap into groove on alternator.

Scheme 155

Release screws for drive belt tensioner.

Scheme 156

11 28 050 Replacing A/C compressor drive belt (M52 / S52 / M52TU / M54 / M56)

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

Necessary preliminary tasks

1. If necessary, remove splash guard.

Model with hydraulic drive belt and tension jack

Remove the dust cab. Push back belt tensioner at bolt connection of guide pulley and remove drive belt.

Scheme 157

Model with mechanical drive belt and tension jack

Press back drive belt tensioner at hexagon head or Torx socket and remove drive belt.

Installation

Check drive belt for coolant and oil residues, replace if necessary.

Install drive belt, make sure it is correctly positioned on belt pulleys.

Scheme 158

11 31 001 Replacing camshaft (M52TU / M54 / M56)

Special tools required

1. 00 9 250
2. 11 2 300
3. 11 3 240
4. 11 3 244
5. 11 3 250
6. 11 3 260
7. 11 3 292
8. 11 4 220
9. 11 6 150
10. 11 6 180

(if necessary inlet or exhaust side)

The inlet or exhaust camshaft can be replaced in the vehicle.

Removal of camshafts is described separately from installation.

The assembly sequence for removal and installation is different.

Remove VANOS adjustment unit . See 11 36 010 Removing And Installing Or Replacing Double VANOS Adjustment Unit (M52TU / M54 / M56) .

Unfasten cylinder for chain tensioning piston.

Scheme 159

Press down secondary chain tensioner at top and lock with special tool 11 3 292.

Scheme 160

Release nuts, remove sensor gear (1).

Scheme 161

Remove plate spring (2).

Scheme 162

Release nuts on inlet side and remove corrugated washer (7).

Scheme 163

Unfasten screws.

Scheme 164

Lift off exhaust and inlet chain wheels together with chain, friction washer (3) and toothed shaft (4).

Note. Toothed shaft (4) is and identical part for exhaust and inlet sides. Store used toothed shafts in order and reinstall on the same side only.

Scheme 165

Remove toothed shaft (5) with toothed sleeve (6).

Scheme 166

Unfasten screws. Remove secondary chain tensioner.

Scheme 167

Release screw-in pin.

Scheme 168

Feed chain wheel (1) towards front out of timing chain (2).

Scheme 169

Note. Timing chain remains positioned over exhaust camshaft.

Scheme 170

If necessary, release screw-in pin on inlet side.

Remove thrust washer.

Scheme 171

Remove sensor gear.

Scheme 172

Scheme 173

Unscrew studs.

Scheme 174

Pull special tool 11 2 300 back until flywheel is no longer secured in position.

Scheme 175

Scheme 176

Scheme 177

Fit special tool 11 3 260 to cylinder head and screw into spark plug threads in cylinders 1 and 4.

Scheme 178

Turn the eccentric shaft to tension the bearing caps.

Unfasten nuts on bearing cover.

Scheme 179

Relieve tension on eccentric shaft and remove special tool 11 3 260.

Remove bearing covers and place to one side in orderly fashion. Remove camshaft.

Scheme 180

Note. If the cylinder head is then to be removed, remove complete bearing strip with bucket tappets.

Locate bucket tappets in bearing strip with special tool 11 3 250.

Lift out complete bearing strip with bucket tappet.

Note. Only re-use used bucket tappets in the same tappet bore.

Scheme 181

Check bearing points on bucket tappets for signs of wear (scoring).

Scheme 182

Bearing strips are marked "A" for exhaust side and "E" for inlet side.

Scheme 183

Note. Note centering dowels on retaining pins at bearing points 2 and 7.

Install bearing strips.

Scheme 184

Installation of camshafts is described separately from removal.

The assembly sequence for removal and installation is different.

Note. Camshafts, bearings and bearing caps, friction washers, all splines on toothed shafts and spline hubs must be oiled before installation.

Comply with following waiting periods after installing camshaft and before cranking engine back to TDC position.

1. Room temperature (20°C) 4 mins
2. 10°C... 20°C 11 mins
3. 0°C... 10°C 30 mins

Pull up timing chain and feed in exhaust camshaft.

Position timing chain on exhaust camshaft.

Scheme 185

Install camshafts so that cam tips on inlet and exhaust valves on 1st cylinder face one another.

Scheme 186

Fit bearing cover.

Note. Bearing caps are marked from exhaust side: A1... A7 for exhaust side E1... E7 for inlet side

Scheme 187

Fit special tool 11 3 260 to cylinder head and screw into spark plug threads in cylinders 1 and 4.

Scheme 188

Turn the eccentric shaft to tension the bearing caps.

Tighten down bearing cover.

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

Remove special tool 11 3 260.

Scheme 189

Align camshafts with open-end wrench.

Scheme 190

Fit special tool 11 3 240 to camshafts on cylinder 6. Align camshafts so that special tool 11 3 240 rests without gaps on cylinder head.

Scheme 191

Attach special tool 11 3 244 to special tool 11 3 240 and locate by way of spark plug thread.

Scheme 192

Lift timing chain and hold under tension.

Turn engine from 30° before TDC position in direction of rotation as far as TDC position.

Scheme 193

Secure crankshaft in firing TDC position with special tool 11 2 300.

Scheme 194

Automatic transmissions only

Illustration does not show automatic transmission.

If special tool 11 2 300 is secured in the correct bore (1), the engine can no longer be cranked at the central bolt.

Scheme 195

Position sensor gear on inlet camshaft.

Scheme 196

Fit thrust washer and tighten down with dowels.

Tightening torque, see 11 31 11AZ in ENGINE - TIGHTENING TORQUES .

Scheme 197

Feed chain wheel onto timing chain so that arrow on chain wheel faces separating face of upper side of cylinder head.

Scheme 198

Insert special tool 11 4 220 in cylinder head and bring adjustment screw into contact with tensioning rail, but do not pretension timing chain yet.

Check arrow on chain wheel to separating face of upper side of cylinder head, reposition chain wheel if necessary.

Scheme 199

Insert and tighten down screw-in pin.

Tightening torque, see 11 31 11AZ in ENGINE - TIGHTENING TORQUES .

Scheme 200

Install secondary chain tensioner.

Scheme 201

Fit toothed sleeve (6) and align to toothed shaft in camshaft so that tooth gaps are opposed.

Scheme 202

Secure toothed shaft (5).

Insert pin of toothed shaft (5) into tooth gaps of splines on camshaft and toothed sleeve (6).

Scheme 203

Push in toothed shaft (5) until the longitudinal holes in the toothed sleeve (6) are positioned centrally with respect to the thread.

Scheme 204

Place chain wheels in special tool 11 6 180, position tooth gap on inlet chain wheel as shown in illustration and feed on chain.

Scheme 205

Remove chain with sprocket wheels positioned from special tool 11 6 180 and so that tooth spaces oppose each other on inlet side.

Scheme 206

Align chain with sprocket wheels so that tooth spaces are positioned exactly over each other on inlet side.

Scheme 207

Secure toothed shaft (4).

Insert pin of toothed shaft (4) into tooth gaps of splines on camshaft and chain wheel.

Scheme 208

Push in toothed shaft (4) until approx. 1 mm of splines can still be seen.

Scheme 209

Note installation direction of corrugated washer (7), "FRONT" lettering must be visible.

Install corrugated washer, tighten nuts by hand but do not tighten down fully yet.

Scheme 210

Insert screws on exhaust side, initially tighten to approx. 5 Nm and then slacken off again half a turn.

Scheme 211

Fit thrust washer (3).

Scheme 212

Note installation direction of cup spring (2), "F" lettering must be visible.

Note. If "F" lettering is no longer visible on an engine that has been run: Install cup spring (2) so that small locating diameter of spring (2) points to sensor gear. Fit cup spring (2) in position.

Scheme 213

Position sensor gear (1) so that arrow on sensor gear faces separating face of upper side of cylinder head.

Install nuts and tighten by hand but do not tighten down fully yet.

Scheme 214

Withdraw toothed shaft (5) up to stop.

Scheme 215

Press down secondary chain tensioner at top and remove special tool 11 3 292.

Scheme 216

Preload tensioning rail with special tool 11 4 220 by rotating adjusting screw with special tool 00 9 250 or standard torque wrench to 0.7 Nm.

Scheme 217

Preload cup spring slightly by pressing on sensor gear (1) and tighten nuts by hand.

Scheme 218

Remove gasket.

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

Keep sealing face clean and free of oil.

Scheme 219

Attach special tool 11 6 150 "without gasket", tighten nuts by hand and then tighten down uniformly until special tool 11 6 150 is in full contact with cylinder head.

Scheme 220

Insert screws (1) on exhaust side and initially tighten to approx. 5 N.m

Scheme 221

Initially tighten nuts (2) on exhaust side and nuts (3) on inlet side to approx. 5 N.m.

Scheme 222

Tighten down screws (1) on exhaust side.

Tightening torque, see 11 31 3AZ in ENGINE - TIGHTENING TORQUES .

Scheme 223

Tighten down nuts (2) on exhaust side and nuts (3) on inlet side.

Tightening torque, see 11 31 11AZ in ENGINE - TIGHTENING TORQUES .

Scheme 224

Pull special tool 11 2 300 back until flywheel is no longer secured in position.

Scheme 225

Remove special tool 11 3 244 and special tool 11 3 240.

Scheme 226

Crank engine twice in direction of rotation until cam tips on inlet and exhaust camshafts on 1st cylinder face one another.

Scheme 227

Secure crankshaft in firing TDC position with special tool 11 2 300.

Scheme 228

Fit special tool 11 3 240 to camshafts.

Scheme 229

Note. The timing is correctly set if the special tool 11 3 240 rests without a gap on the cylinder head or protrudes up to 1 mm to the inlet side. The timing must be reset if the special tool 11 3 240 protrudes to the exhaust side.

Scheme 230

Remove special tool 11 6 150.

Install VANOS adjustment unit . See 11 36 010 Removing And Installing Or Replacing Double VANOS Adjustment Unit (M52TU / M54 / M56) .

Assemble engine.

Scheme 231

11 31 005 Checking camshaft timing (M52TU / M54 / M56)

Special tools required

1. 00 9 250
2. 11 2 300
3. 11 3 240
4. 11 3 450
5. 11 4 220

Necessary preliminary tasks

1. Remove cylinder head cover See .
2. Remove all spark plugs . See «12 12 011 REPLACING ALL SPARK PLUGS»(/bmw/z4/e85e86-2002-2005/remont/gauges-instrument-panels/#engine-electrical-system-repair__12-12-011-replacing-all-spark) .

Detach cover for inlet camshaft.

Scheme 232

Remove cylinder for chain tensioning piston.

Scheme 233

Install special tool 11 4 220.

Fit adjusting screw to bow cover.

Scheme 234

Preload tensioning rail with special tool 11 4 220 by rotating adjusting screw with special tool 00 9 250 or standard torque wrench to 0.7 Nm.

Scheme 235

Unscrew oil pressure pipe.

Scheme 236

Mount special tool 11 3 450 with banjo bolt of oil pressure line.

Scheme 237

Scheme 238

Connect compressed air (2 to 8 bar).

Scheme 239

Note. When the engine is switched off, it is possible that the camshafts are not in their initial positions. With the compressed air supply connected, rotate the engine to return the camshafts to their initial positions.

With compressed air supply connected, crank engine at least two revolutions in direction of rotation until cam tips on inlet and exhaust camshafts on 1st cylinder face each other.

Scheme 240

Pull dust guard out of the special tool bore.

Scheme 241

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

Scheme 242

Automatic transmissions only

Illustration does not show automatic transmission.

If special tool 11 2 300 is secured in the correct bore (1), the engine can no longer be cranked at the central bolt.

Scheme 243

Unscrew studs.

Scheme 244

Place special tool 11 3 240 on camshafts.

Scheme 245

Note. The timing is correctly set if the special tool 11 3 240 rests without a gap on the cylinder head or protrudes up to 1 mm to the inlet side. The timing must be reset if the special tool 11 3 240 protrudes to the exhaust side. If necessary, adjust camshaft timing.

Scheme 246

Detach compressed air connection.

Remove special tool 11 3 450.

Scheme 247

Fit oil pressure line with new seals.

Tightening torque, see 11 36 2AZ in ENGINE - TIGHTENING TORQUES .

Scheme 248

Remove special tool 11 3 240.

Scheme 249

Remove special tool 11 2 300.

Install dust guard from inspection bore.

Scheme 250

Unfasten and remove special tool 11 4 220.

Scheme 251

Install cylinder for chain tensioning piston .

Assemble engine.

Scheme 252

11 31 090 Removing and installing/replacing chain tensioning piston (M52 / M52TU / M54 / M56)

Unfasten cylinder for chain tensioning piston.

Installation

Replace sealing ring.

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

Scheme 253

Arrangement of components

Scheme 254

1. Cylinder for chain tensioning piston
2. Sealing ring
3. Spring
4. Piston

11 31 505 Adjusting camshaft timing (M52TU / M54 / M56)

Special tools required

1. 00 9 250
2. 11 2 300
3. 11 3 240
4. 11 3 244
5. 11 3 292
6. 11 4 220
7. 11 5 180
8. 11 6 150

(refer to 11 31 005 CHECKING CAMSHAFT TIMING (M52TU / M54 / M56) )

Before carrying out adjustment work

Check camshaft timing .

Crank engine in direction of rotation until cam tips on inlet and exhaust camshafts on 1st cylinder face one another.

Scheme 255

Secure crankshaft with special tool 11 2 300 in TDC position of 1st cylinder.

X3 only

Secure crankshaft with special tool 11 5 180 in TDC position of 1st cylinder.

Scheme 256

Unscrew studs.

Scheme 257

Remove double VANOS adjustment unit . See 11 36 010 Removing And Installing Or Replacing Double VANOS Adjustment Unit (M52TU / M54 / M56) .

Press down top of chain tensioner and lock off with special tool 11 3 292.

Scheme 258

Remove cylinder for chain tensioning piston.

Scheme 259

Install special tool 11 4 220.

Fit adjusting screw to bow cover.

Scheme 260

Release screws (1) by half a turn.

Scheme 261

Release nuts (2) by two turns.

Release nuts (3) by one turn.

Scheme 262

Pull out toothed shaft (4) until approx. 1 mm of splines can be seen.

Scheme 263

Withdraw toothed shaft (5) up to stop.

Scheme 264

Fit special tool 11 3 240 to camshafts on cylinder 6. Align camshafts so that special tool 11 3 240 rests without gaps on cylinder head.

Scheme 265

Attach special tool 11 3 244 to special tool 11 3 240 and locate by way of spark plug thread.

Scheme 266

Press down chain tensioner at top and remove special tool 11 3 292.

Scheme 267

Preload tensioning rail with special tool 11 4 220 by rotating adjusting screw with special tool 00 9 250 or standard torque wrench to 0.7 Nm.

Scheme 268

Preload cup spring slightly by pressing on sensor gear (1) and tighten nuts by hand.

Scheme 269

Remove gasket.

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

Keep sealing face clean and free of oil.

Scheme 270

If gasket remains underneath special tool 11 6 150, camshaft timing will be "incorrectly" set.

Attach special tool 11 6 150 "without gasket", tighten nuts by hand and then tighten down uniformly until special tool 11 6 150 is in full contact with cylinder head.

Scheme 271

Insert screws (1) on exhaust side and initially tighten to approx.

5 Nm

Scheme 272

Initially tighten nuts (2) on exhaust side and nuts (3) on inlet side to approx. 5 Nm.

Scheme 273

Tighten down screws (1) on exhaust side.

Tightening torque, see 11 31 3AZ in ENGINE - TIGHTENING TORQUES .

Scheme 274

Tighten down nuts (2) on exhaust side and nuts (3) on inlet side.

Tightening torque, see 11 31 11AZ in ENGINE - TIGHTENING TORQUES .

Scheme 275

Pull special tool 11 2 300 / 11 5 180 back until flywheel is no longer secured.

Scheme 276

Remove special tool 11 3 244 and special tool 11 3 240.

Scheme 277

Crank engine twice in direction of rotation until cam tips on inlet and exhaust camshafts on 1st cylinder face one another.

Scheme 278

Secure crankshaft in firing TDC position with special tool 11 2 300.

X3 only

Secure crankshaft with special tool 11 5 180 in TDC position of 1st cylinder.

Scheme 279

Fit special tool 11 3 240 to camshafts.

Scheme 280

Note. The timing is correctly set if the special tool 11 3 240 rests without a gap on the cylinder head or protrudes up to 1 mm to the inlet side. The timing must be reset if the special tool 11 3 240 protrudes to the exhaust side.

Scheme 281

Unfasten and remove special tool 11 4 220.

Scheme 282

Install cylinder for chain tensioning piston .

Scheme 283

Remove special tool 11 2 300 / 11 5 180.

Scheme 284

Remove special tool 11 6 150.

Install VANOS adjustment unit . See 11 36 010 Removing And Installing Or Replacing Double VANOS Adjustment Unit (M52TU / M54 / M56) .

Assemble engine.

Scheme 285

11 34 552 Removing and installing or replacing all valves (M52 / S52 / M52TU / M54 / M56)

(cylinder head removed)

Preliminary tasks are described in Disassembling and assembling cylinder head .

Replace valve stem seals . See 11 34 560 Replacing All Valve Stem Seals (M52 / S52 / M52TU / M54 / M56) .

Remove valves from cylinder head.

If necessary, check valve guide for wear .

If necessary, ream valve guide .

If necessary, remachine valve seat .

Arrangement

Scheme 286

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

11 34 560 Replacing all valve stem seals (M52 / S52 / M52TU / M54 / M56)

Special tools required

1. 11 1 200
2. 11 1 480
3. 11 1 960

(cylinder head removed)

Preliminary tasks are described in Disassembling and assembling cylinder head .

Remove all valve springs . See 11 34 715 Replacing All Valve Springs (M52 / S52 / M52TU / M54 / M56) .

Remove valve stem seal with special tool 11 1 480.

Scheme 287

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 288

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

Scheme 289

11 34 715 Replacing all valve springs (M52 / S52 / M52TU / M54 / M56)

Special tools required

1. 11 0 342
2. 11 0 345
3. 11 1 045
4. 11 1 065
5. 11 1 441
6. 11 3 030
7. 11 3 250

(cylinder head removed)

Preliminary tasks are described in Disassembling and assembling cylinder head .

Brace bucket tappets with special tool 11 3 250.

Lift out bearing strip with bucket tappet.

Installation

Only re-use used bucket tappets in the same tappet bore.

Scheme 290

Arrange bucket tappets by cylinder and place on special tool 11 3 030 in correct order.

Scheme 291

Insert special tool 11 1 441 from below in special tool 11 1 065 and secure with special tool 11 1 045.

Scheme 292

Align special tool 11 0 345 in direction of valve shaft and select appropriate groove in special tool 11 0 342.

Scheme 293

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

Remove valve spring and plate spring.

Scheme 294

Arrangement

Scheme 295

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

11 36 010 Removing and installing or replacing double VANOS adjustment unit (M52TU / M54 / M56)

Special tools required

1. 00 9 250
2. 11 2 300
3. 11 3 240
4. 11 3 450
5. 11 4 220
6. 11 6 170

Necessary preliminary tasks

1. Remove intake filter housing with air-mass flow sensor
2. Remove cylinder head cover . See «11 12 000 Removing And Installing, Sealing Cylinder Head Cover (M52TU / M54 / M56)»(/bmw/z4/e85e86-2002-2005/remont/mechanical/#engine-repair-m54__11-12-000-removing-and-installing) .
3. Remove spark plugs . See «12 12 011 REPLACING ALL SPARK PLUGS»(/bmw/z4/e85e86-2002-2005/remont/gauges-instrument-panels/#engine-electrical-system-repair__12-12-011-replacing-all-spark) .

E85 only

1. Remove radiator cover . See «RADIATOR COVER»(/bmw/z4/e85e86-2002-2005/remont/cooling-fan/#cooling-fans__radiator-cover) .
2. Drain coolant from radiator. See «17 00 005 DRAINING OFF AND TOPPING UP COOLANT»(/bmw/z4/e85e86-2002-2005/remont/cooling-system-mechanical/#cooling-system-repair__17-00-005-draining-off-and) .

Note. Protect drive belt against emerging coolant.

1. Remove right coolant hose
2. Remove solenoid valve for exhaust side

Removal

Removal of double VANOS adjustment unit is described separately from installation. Assembly sequence for removal and installation is different.

Detach plastic cover for inlet camshaft.

Scheme 296

Unscrew oil pressure pipe.

Scheme 297

Mount special tool 11 3 450 with banjo bolt of oil pressure line.

Scheme 298

When the compressed air supply is connected, several drops of oil are sprayed out of the bore.

Scheme 299

Connect compressed air (2 to 8 bar).

Scheme 300

Note. When the engine is switched off, it is possible that the camshafts are not in their initial positions. With the compressed air supply connected, rotate the engine to return the camshafts to their initial positions. With compressed air supply connected, crank engine at least two revolutions in direction of rotation until cam tips on inlet and exhaust camshafts on 1st cylinder face each other.

Scheme 301

Pull dust guard out of the special tool bore.

Scheme 302

Secure crankshaft in firing TDC position with special tool 11 2 300.

Scheme 303

Automatic transmissions only

Illustration does not show automatic transmission.

If special tool 11 2 300 is secured in the correct bore (1), the engine can no longer be cranked at the central bolt.

Scheme 304

Unscrew studs.

Scheme 305

Secure camshafts with special tool 11 3 240.

Scheme 306

Detach compressed air connection.

Note. special tool 11 3 450 still remains fitted.

Scheme 307

Make sure no oil runs onto belt drive. Remove any remnants of oil immediately with cleaning cloth.

Remove screw plugs, catch escaping oil on inlet and exhaust sides.

Scheme 308

Remove sealing caps with special tool 11 6 170 or with commercially available short flat nose pliers.

E85

Use commercially available offset flat nose pliers.

Scheme 309

Release fitting screws on inlet and exhaust sides.

Scheme 310

Detach plug connections from camshaft sensor and solenoid valves on exhaust and inlet sides.

Scheme 311

Unscrew suspension eye.

Scheme 312

Release nuts and remove double VANOS adjustment unit.

Scheme 313

Installation

Installation of double VANOS adjustment unit is described separately from removal. Assembly sequence for removal and installation is different.

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

Keep sealing faces clean and free of oil. Apply a thin and even coat of sealing compound Drei Bond 1209 to contact surface edges of separating face between cylinder head and double VANOS adjustment unit.

Replace seal.

Scheme 314

Install and secure double VANOS adjustment unit.

Scheme 315

Attach plug connections of camshaft sensor and solenoid valves on exhaust and inlet sides.

Scheme 316

Insert fitting screws for hydraulic piston on toothed shaft on inlet and exhaust sides and tighten down.

Tightening torque, see 11 36 4AZ in ENGINE - TIGHTENING TORQUES .

Scheme 317

Replace sealing caps and install with special tool 11 6 170 or with commercially available short flat nose pliers.

E85

Use commercially available offset flat nose pliers.

Scheme 318

Insert screw plugs with new sealing rings and tighten down.

Tightening torque, see 11 36 3AZ in ENGINE - TIGHTENING TORQUES .

Scheme 319

Fit suspension lug.

Scheme 320

Note. If the double VANOS adjustment unit has been replaced, you must check and, if necessary, adjust the camshaft timing.

If work has been carried out which has "no" effect on the timing and it is assured that the timing adjustment is correct, the timing check described in the following does not have to be conducted.

Remove cylinder for chain tensioning piston.

Scheme 321

Insert special tool 11 4 220 in cylinder head and bring adjustment screw into contact with tensioning rail.

Scheme 322

Preload tensioning rail with special tool 11 4 220 by rotating adjusting screw with special tool 00 9 250 or standard torque wrench to 0.7 Nm.

Scheme 323

Pull special tool 11 2 300 back until flywheel is no longer secured in position.

Scheme 324

Remove special tool 11 3 240.

Scheme 325

Scheme 326

Connect compressed air (2 to 8 bar).

Scheme 327

With compressed air supply connected, crank engine twice in direction of rotation until cam tips on inlet and exhaust camshafts on 1st cylinder face each other.

Scheme 328

Secure crankshaft with special tool 11 2 300 in TDC position of 1st cylinder.

Scheme 329

Check camshaft setting

Fit special tool 11 3 240 to camshafts.

Scheme 330

Note. The timing is correctly set if the special tool 11 3 240 rests without a gap on the cylinder head or protrudes up to 1 mm to the inlet side.

The timing must be reset if the special tool 11 3 240 protrudes to the exhaust side.

If necessary, adjust camshaft timing .

Scheme 331

Detach compressed air connection.

Remove special tool 11 3 450.

Scheme 332

Fit oil pressure line with new seals.

Tightening torque, see 11 36 2AZ in ENGINE - TIGHTENING TORQUES .

Scheme 333

Unfasten and remove special tool 11 4 220.

Scheme 334

Install cylinder for chain tensioning piston .

Scheme 335

Remove special tool 11 3 240.

Scheme 336

Remove special tool 11 2 300.

Assemble engine.

Scheme 337

11 36 570 Replacing solenoid valve for inlet side on VANOS adjustment unit

Special tools required

1. 32 2 110

Necessary preliminary tasks

1. Read out fault memory of DME control unit
2. Check stored fault messages
3. Switch off ignition

Unlock hose (1) and detach.

Unlock plug (2) and remove.

Scheme 338

Note. Once it has been removed, oil drips from the solenoid valve. Have a cleaning cloth ready. Make sure no oil drips onto the belt drive. Remove any remnants of oil immediately with cleaning cloth. Do not damage oil line when releasing solenoid valve. Release solenoid valve with special tool 32 2 110.

Installation

Tightening torque, see 11 36 1AZ in ENGINE - TIGHTENING TORQUES .

Now clear the fault memory.

Scheme 339

11 36 575 Replacing solenoid valve for exhaust side on VANOS adjustment unit

Special tools required

1. 11 6 420

Necessary preliminary tasks

1. Read out fault memory of DME control unit
2. Check stored fault messages
3. Switch off ignition

E85 only

1. Remove fluid tank for windshield washer system

Unlock plug (1) and remove.

Cut through cable tie (2).

Scheme 340

Note. Once it has been removed, oil drips from the solenoid valve. Have a cleaning cloth ready. Make sure no oil drips onto the belt drive. Remove any remnants of oil immediately with cleaning cloth. Release solenoid valve with special tool 11 6 420.

Installation

Tightening torque, see 11 36 1AZ in ENGINE - TIGHTENING TORQUES .

Now clear the fault memory.

Scheme 341

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

Note. For engine oil pressure to be checked, oil pressure switch must be removed and special tools must be installed and connected.

To avoid an excess discharge of oil when removing oil pressure switch

Unscrew oil filter cap; the engine oil flows out of the oil filter housing into the oil sump.

Installation

Replace sealing ring.

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

Remove oil pressure switch.

Installation

Tightening torque, see 12 61 1AZ in ENGINE - TIGHTENING TORQUES .

Install special tool 11 4 050 with sealing ring (1) in place of oil pressure switch.

Scheme 342

Checking engine oil pressure with DIS Tester

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

Checking engine oil pressure with pressure gauge

Install special tool 13 3 063 and special tool 13 3 061 (pressure gauge).

Start engine and check engine oil pressure.

Specified value .

Scheme 343

11 41 000 Removing and installing/replacing oil pump (M52TU / M54 / M56)

Remove oil sump . See 11 13 000 Removing And Installing, Sealing Or Replacing Oil Sump (M52TU / M54 / M56) .

Installation

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

Scheme 344

Remove sprocket with chain.

Installation

Align splines of chain wheel and oil pump shaft to each other.

Scheme 345

Version 1

Oil pump integrated in oil scraper

Release screws (1), remove oil pump with oil scraper.

Scheme 346

Version 2

Oil pump and oil scraper - two parts

Release screws and remove oil pump intake pipe.

Scheme 347

Version 2

Oil pump and oil scraper - two parts

Release screws and remove oil pump.

Scheme 348

Installation

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

Scheme 349

Installation

Replace O-ring on intake pipe.

Scheme 350

If necessary, remove control piston.

Press sleeve downwards with suitable drift.

Remove circlip.

Scheme 351

Installation

Scheme 352

1. Control plunger
2. Spring
3. Sleeve
4. O-ring (replace)
5. Circlip

11 42 020 Removing and installing complete full-flow oil filter (M52 / S52 / M52TU / M54 / M56)

Remove intake air housing with air-mass flow sensor.

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 the section 00 00... ENGINE OIL SERVICE .

Remove GENERATOR .

If necessary, empty supply tank for power steering.

If necessary, remove supply tank (lines remain connected).

If necessary, remove vane pump for power steering (lines remain connected).

If necessary, remove alternator drive belt tensioner.

Remove connector for oil pressure switch.

If necessary, disconnect plug for oil temperature switch.

Disconnect oil pressure line for VANOS adjustment unit from oil filter housing.

Unfasten screws and remove complete full-flow oil filter.

Scheme 353

Installation

Check dowel sleeves for damage and correct installation position.

Scheme 354

Installation

Replace seal.

Top up engine oil.

Scheme 355

11 51 000 Removing and installing/replacing water pump (M54)

Necessary preliminary tasks

1. Remove suction filter housing .
2. Remove alternator drive belt . See «GENERATOR DRIVE BELT»(/bmw/z4/e85e86-2002-2005/remont/charging-system/#generators-regulators__generator-drive-belt) .
3. Secure engine in installation position with special tool .

Drain and dispose of coolant . See 17 00 005 DRAINING OFF AND TOPPING UP COOLANT .

Installation

Replace seal.

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

Vent cooling system and check for leaks.

Release engine mount at top left.

Installation

Tightening torque, see 22 11 1AZ in ENGINE - TIGHTENING TORQUES .

Raise engine with special tool approx. 3 cm to ensure removal of water pump.

Measurement A = 3 cm

Scheme 356

Release nuts and remove belt pulley.

Scheme 357

Unscrew nuts.

Tighten two screws (M 6) into thread (1) of water pump (2) and press water pump uniformly out of timing case.

Scheme 358

Installation

Replace sealing ring (1) and coat with antiseize agent.

Scheme 359

11 53 000 Removing and installing/replacing coolant thermostat (M54)

Necessary preliminary tasks

1. Remove radiator cover . See «RADIATOR COVER»(/bmw/z4/e85e86-2002-2005/remont/cooling-fan/#cooling-fans__radiator-cover) .
2. Remove fan cowl . See «FAN COWL»(/bmw/z4/e85e86-2002-2005/remont/cooling-fan/#cooling-fans__fan-cowl) .
3. Drain off and top up coolant . See «17 00 005 DRAINING OFF AND TOPPING UP COOLANT»(/bmw/z4/e85e86-2002-2005/remont/cooling-system-mechanical/#cooling-system-repair__17-00-005-draining-off-and) .

Illustrations show E46.

Pull locks and disconnect water hoses.

Scheme 360

Loosen nut (1).

Release screws on thermostat housing, remove thermostat housing.

Scheme 361

Installation

Keep sealing faces clean and free of oil.

Scheme 362

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

Installation

Replace gasket (1).

Scheme 363

11 61 050 Removing and installing intake air manifold (M54)

Necessary preliminary tasks

1. Instructions for disconnecting and connecting battery . Disconnect negative battery lead.
2. Remove engine cover .
3. Remove left tension strut . See «51 23 265 REMOVING AND INSTALLING/REPLACING LEFT AND RIGHT GAS STRUT SHOCKS»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair) .
4. Remove intake filter top section .
5. Remove intake pipe .
6. Remove sound generator .

Unclip plug connections (1) from holders.

Scheme 364

Press lock and detach vent hose.

Scheme 365

Remove clips (1).

Detach terminal strip (3) from fuel injectors and place to one side.

Scheme 366

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

Instructions for removing and installing fuel hoses.

Unclip fuel line (1) from holder (2).

Unlock and detach fuel line (1).

Scheme 367

Disconnect plug connection (1) on tank venting valve.

Remove tank venting valve from retainer (2) on manifold.

Scheme 368

Press lock and detach return line from oil dipstick guide tube.

Unclip plug connection (1) for knock sensors from holder.

Release nut (2) on manifold support.

Scheme 369

Release nuts on manifold.

Note. Engines with air injection: Detach vacuum line on reverse side of intake air manifold.

Remove intake air manifold.

Scheme 370

Installation

Check gaskets on all cylinders and replace if necessary.

Scheme 371

11 61 095 Removing and installing/replacing DISA adjustment unit

Turn off ignition.

E46 only

Disconnect intake hose between air-mass flow sensor and connecting piece.

Unlock plug (1) and detach from DISA adjustment unit (DISA = differentiated air intake system).

Scheme 372

Release screws.

Withdraw DISA adjustment unit (1) from intake air manifold.

Scheme 373

18 40 030 Removing and installing/replacing both exhaust manifolds (M54)

Necessary preliminary tasks

1. Secure engine in installation position
2. Remove front engine underguard
3. Remove reinforcement plate
4. Remove entire exhaust system .
5. Remove bracket between exhaust manifold and transmission
6. Detach grounding cable from body
7. Remove right engine support arm with engine mount
8. Release nuts on heat shield at bottom
9. Remove right tension strut . See «51 23 265 REMOVING AND INSTALLING/REPLACING LEFT AND RIGHT GAS STRUT SHOCKS»(/bmw/z4/e85e86-2002-2005/remont/door-locks-anti-theft-systems/#body-equipment-repair) .
10. Remove air pump
11. Release heat shield at top and remove

Note. The oxygen sensors are in danger of being damaged when the exhaust manifolds are removed and installed.

Remove oxygen control sensors .

Remove cover from injection valves.

Note. Do not mix up oxygen monitor sensors for cylinders 1 to 3 and 4 to 6 at plug connection to wiring harness. Mark plug connections. Unclip the cable from the retainer. Disconnect plug connection. Unclip cable on rear side of engine from cable guide.

Remove oxygen monitor sensor from cylinders 1 to 3 from above.

Scheme 374

Note. Rear exhaust manifold with catalytic converter can only be removed after front exhaust manifold with catalytic converter has first been removed.

Remove front exhaust manifold with catalytic converter.

Remove oxygen monitor sensor from cylinders 4 to 6.

Unscrew nuts.

Remove exhaust manifold (1).

Installation

Clean sealing faces, replace gaskets.

Coat threads with copper paste.

Replace nuts.

Tightening torque, see 11 62 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 375

18 40 050 Removing and installing/replacing front exhaust manifold (M54)

Necessary preliminary tasks

1. Secure engine in installation position .
2. Remove front splash guard.
3. Remove reinforcement plate .
4. Remove complete exhaust system .
5. Remove bracket between exhaust manifold and transmission.
6. Detach grounding cable from body.
7. Remove right engine support arm with engine mount.
8. Release nuts on heat shield at bottom.
9. Remove right tension strut .
10. Remove air pump .
11. Release heat shield at top and remove.

Note. The oxygen sensors are in danger of being damaged when the exhaust manifolds are removed and installed.

Remove front oxygen control sensor .

Remove cover from injection valves.

Note. Do not mix up oxygen monitor sensors for cylinders 1 to 3 and 4 to 6 at plug connection to wiring harness. Mark plug connections. Unclip the cable from the retainer. Disconnect plug connection. Unclip cable on rear side of engine from cable guide.

Remove oxygen monitor sensor from cylinders 1 to 3 from above.

Scheme 376

Unscrew nuts.

Remove exhaust manifold (1).

Installation

Clean sealing faces, replace gaskets.

Coat threads with copper paste.

Replace nuts.

Tightening torque, see 11 62 1AZ in ENGINE - TIGHTENING TORQUES .

Scheme 377

18 40 060 Removing and installing/replacing rear exhaust manifold (M54)

Rear exhaust manifold with catalytic converter can only be removed after front exhaust manifold with catalytic converter has first been removed.

Procedure is described in the Repair Manual headed "Removing and installing/replacing both exhaust manifolds ".

11 72 000 Removing and installing/replacing air pump (M54)

Unlock and detach pressure line (1).

Unfasten screws.

Lift air pump (2), unlock and disconnect plug connection.

Scheme 378

11 78 513 Replacing both oxygen control sensor (M54)

Special tools required

1. 11 7 020

Necessary preliminary tasks

Read out fault memory of control unit of Digital Motor Electronics (DME).

Switch off ignition.

Unclip plug connection (1) and disconnect.

Release both oxygen sensors (2) with special tool 11 7 020.

Scheme 379

Installation

Threads of new oxygen sensors are already coated with Never Seez compound.

If an oxygen sensor is reused, only apply a thin and uniform coat of Never Seez compound to thread.

Oxygen sensor section projecting into exhaust system branch must not be cleaned or come into contact with lubricant.

Pay attention to cable routing of oxygen sensors.

Use special tool 11 7 020 to tighten down oxygen sensor.

Tightening torque, see 11 78 1AZ in ENGINE - TIGHTENING TORQUES .

Cover oxygen sensors when applying underseal.

Installation

Check stored fault messages.

Now clear the fault memory.

11 78 611 Replacing oxygen monitor sensor (cylinders 1-3)

Special tools required

1. 11 7 020

Necessary preliminary tasks

Read out fault memory of control unit of Digital Motor Electronics (DME).

Switch off ignition.

Remove cover from injector valves.

Unclip cable and plug.

Disconnect plug.

Scheme 380

Release oxygen monitor sensor from above with special tool 11 7 020.

Scheme 381

Installation

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

If an oxygen monitor sensor is reused, only apply a thin and uniform coat of Never Seez compound to thread.

Oxygen monitor sensor section projecting into exhaust system branch must not be cleaned or come into contact with lubricant.

Cover oxygen monitor sensor when applying underseal.

Tightening torque, see 11 78 1AZ in ENGINE - TIGHTENING TORQUES .

Installation

Check stored fault messages.

Now clear the fault memory.

11 78 612 Replacing oxygen monitor sensor (cylinders 4-6)

Special tools required

1. 11 7 020
2. 11 7 030
3. 11 9 150

Necessary preliminary tasks

1. Read out fault memory of control unit of Digital Motor Electronics (DME).
2. Switch off ignition.
3. Remove cover from injector valves.
4. Remove reinforcement plate.

Unclip cable and plug.

Disconnect plug.

Scheme 382

Note. For a better overview, this work step is shown on an exhaust manifold that has been removed.

Automatic transmission

Release oxygen monitor sensor with special tool 11 7 030 in conjunction with special tool 11 9 150.

Scheme 383

Manual transmission

Release oxygen monitor sensor with special tool 11 7 020.

Installation

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

If an oxygen monitor sensor is reused, only apply a thin and uniform coat of Never Seez compound to thread.

Oxygen monitor sensor section projecting into exhaust system branch must not be cleaned or come into contact with lubricant.

Cover oxygen monitor sensor when applying underseal.

Pay attention to cable routing for oxygen monitor sensor.

Automatic transmission

Installation

When special tool 11 9 150 is used in conjunction with special tool 11 7 030, 53 Nm on the torque wrench dial corresponds to an actual tightening torque of 50 Nm.

To tighten down oxygen monitor sensor, fit torque wrench and special tools 11 7 030 / 11 9 150 as shown in illustration.

Check stored fault messages.

Now clear the fault memory.

Scheme 384

Manual transmission

Installation

Tighten down oxygen monitor sensor with special tool 11 7 020.

Tightening torque, see 11 78 1AZ in ENGINE - TIGHTENING TORQUES .

Check stored fault messages.

Now clear the fault memory.

Scheme 385

See also:
• ENGINE - TIGHTENING TORQUES
• 12 12 011 REPLACING ALL SPARK PLUGS
• REMOVAL & INSTALLATION (S5D 200G/S5D 250G/M52
• REMOVAL & INSTALLATION (GS6S37BZ SMG)
• FAN COWL
• 51 23 265 REMOVING AND INSTALLING/REPLACING LEFT AND RIGHT GAS STRUT SHOCKS
• 17 00 005 DRAINING OFF AND TOPPING UP COOLANT
• A/C COMPRESSOR DRIVE BELT
• 12 13 511 IGNITION COILS (M54)
• 17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR LEAKS
• STEERING GEAR
• GENERATOR DRIVE BELT
• RADIATOR COVER
• 00 00... ENGINE OIL SERVICE
• GENERATOR
• Emission Control, Oxygen Sensor
• 11 61 050 Removing And Installing Intake Air Manifold (M54)
• Coolant Thermostat
• 11 36 010 Removing And Installing Or Replacing Double VANOS Adjustment Unit (M52TU / M54 / M56)
• 11 31 001 Replacing Camshaft (M52TU / M54 / M56)
• 11 34 715 Replacing All Valve Springs (M52 / S52 / M52TU / M54 / M56)
• 11 34 560 Replacing All Valve Stem Seals (M52 / S52 / M52TU / M54 / M56)
• 11 34 552 Removing And Installing Or Replacing All Valves (M52 / S52 / M52TU / M54 / M56)
• 11 12 600 Reaming A Valve Guide (M52 / S52 / M52TU / M54 / M56)
• 11 23 010 Removing And Installing Or Replacing Vibration Damper (M52TU / M54 / M56)
• 11 13 000 Removing And Installing, Sealing Or Replacing Oil Sump (M52TU / M54 / M56)
• 11 14 141 Replacing Radial Seal In Lower Timing Case Cover
• 11 21 531 Replacing All Main Crankshaft Bearing Shells (M52 / S52 / M52TU / M54 / M56)
• 11 24 571 Replacing all connecting rod bearings (M52 / S52 / M52TU / M54 / M56)
• 11 21 571 Replacing Grooved Ball Bearing In Crankshaft (M52 / S52 / M52TU / M54 / S50 / S54)
• 11 25 530 Removing And Installing Or Replacing All Pistons (M52 / S52 / M52TU / M54 / M56)
• 11 41 000 Removing And Installing/Replacing Oil Pump (M52TU / M54 / M56)
• 11 28 050 Replacing A/C Compressor Drive Belt (M52 / S52 / M52TU / M54 / M56)
• 11 28 010 Replacing Alternator Drive Belt (M52 / S52 / M52TU / M54 / M56)
• 11 31 005 CHECKING CAMSHAFT TIMING (M52TU / M54 / M56)
• 11 12 000 Removing And Installing, Sealing Cylinder Head Cover (M52TU / M54 / M56)