Engine - Repair - Cooper (N12 Engine): Other MINI Cooper I

00 DANGER OF POISONING IF OIL IS INGESTED/ABSORBED THROUGH THE SKIN

Danger of poisoning!

Ingesting oil or absorbing through the skin may cause poisoning!

Possible symptoms are

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

Protective measures/rules of conduct

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

First aid measures

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

00 RISK OF INJURY IF OIL COMES INTO CONTACT WITH EYES AND SKIN

Danger of injury!

Contact with eyes or skin may result in injury!

Possible symptoms are

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

Protective measures/rules of conduct

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

First aid measures

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 INFORMATION FOR WORKING ON VEHICLES WITH AUTOMATIC ENGINE START-STOP SYSTEM (MSA)

Observe safety precautions when working on MSA vehicles.

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

MSA function is deactivated by

Scheme 481

1. Deactivate MSA by means of button (1) in passenger compartment
2. Open seat belt buckle and driver's door
3. Open engine bonnet/hood and ensure that engine hood/bonnet contact is not in workshop mode Workshop mode A = 10 mm Basic setting (engine hood/bonnet open) B = 7 mm

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

Scheme 482

When working with diagnosis tools

1. Observe instructions in diagnosis tool

Note. For further information on automatic engine start-stop system (MSA)

1. Refer to «ELECTRICAL SYSTEMS»(ref-265668-S03130035642007092500000) .

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.

11 00 REMOVING AND INSTALLING/REPLACING ACOUSTIC COVER (N12)

Release screws (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Release acoustic cover at retainers (2).

Lift off acoustic cover in direction of arrow.

Scheme 483

11 00 050 REMOVING AND INSTALLING ENGINE WITH TRANSMISSION (N12)

Special tools required

1. 11 0 260

Necessary preliminary tasks

1. Lift engine hood into assembly position.
2. Remove exhaust system.
3. Drain engine oil.
4. Disconnect negative battery lead.
5. Remove both drive shafts.
6. Remove air cleaner housing.
7. Remove fan cowl with electric fan.
8. Detach all coolant hoses from engine.
9. Detach vacuum line from brake booster.
10. Unfasten engine wiring harness and lay to one side.
11. Remove complete front panel

Attach special tool 11 0 260 to lifting eye (1) at engine end

Scheme 484

Attach special tool 11 0 260 to lifting eye (1) at transmission end

Scheme 485

Release transmission and engine mounts.

Remove engine with special tool 11 0 260 towards front.

Scheme 486

Assemble engine.

Check function of DME.

11 12 000 REMOVING AND INSTALLING/SEALING CYLINDER HEAD COVER (N12)

Necessary preliminary tasks

1. Remove acoustic cover
2. Remove rod-type ignition coils.

Disconnect plug connection at ignition coils (1).

Unfasten engine wiring harness (2) at cylinder head cover.

Release ground connection (3).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 487

Disconnect plug connections (2 and 3).

If necessary, release sensors (4 and 6).

Unfasten engine wiring harness (1) at cylinder head cover.

Scheme 488

Unfasten engine vent hose at lock (1) in direction of arrow.

Detach engine vent hose in direction of arrow.

Scheme 489

Unfasten engine wiring harness (1) at cylinder head cover.

Scheme 490

Disconnect plug connection (1) at coolant sensor.

Scheme 491

Release bolts in areas (1 and 2).

Scheme 492

Replace seal (1).

Replace all seals (2).

Installation

Clean all sealing surfaces.

Scheme 493

Installation

Observe tightening sequence (1 to 13).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 494

Assemble engine.

11 12 100 REMOVING AND INSTALLING/SEALING CYLINDER HEAD (N12)

Special tools required

1. 11 2 250
2. 11 4 471
3. 11 4 472
4. 11 9 590
5. 11 9 630

Necessary preliminary tasks

1. Remove exhaust system.
2. Drain coolant.
3. Drain engine oil.
4. Remove exhaust manifold.
5. Remove intake air manifold.
6. Remove oil dipstick.
7. Detach coolant hoses from cylinder head.
8. Remove cylinder head cover. Refer to «12 CYLINDER HEAD WITH COVER»(ref-264948-S25920930892007092000000) .
9. Remove inlet and exhaust adjustment unit.

Secure crankshaft with special tool 11 9 590 .

Scheme 495

Note. Remove and install cylinder head in installed state. Suspend engine with engine crane (1) from lifting eye (2).

Scheme 496

Note. Remove and install cylinder head in installed state. Move front panel into assembly position.

Release upper alternator screws, do not remove alternator.

Remove right engine mount.

Secure special tool 11 9 630 with standard bolts (1 and 2).

Scheme 497

Release screws (1).

Installation

Only during assembly is the timing chain lifted out with a hook.

Scheme 498

Release screw (1).

Scheme 499

Release cylinder head bolts with special tool 11 2 250.

Scheme 500

Release cylinder head bolts from outside inwards (10 to 1).

Note. Remove shims with a magnet. Illustration shows camshafts removed.

Scheme 501

Use special tool 11 4 471 to remove coarse gasket remnants from sealing faces of cylinder head and crankcase.

Scheme 502

Remove fine gasket remnants with special tool 11 4 472 .

There must not be any coolant, water or oil present in the pocket holes (risk of corrosion and cracking) .

Clean all pocket holes.

Replace cylinder head gasket.

Scheme 503

Attach shims to cylinder head bolts.

Shims can drop into the engine (risk of damage!) .

Secure cylinder head bolts from inside outwards (1 to 10).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Note. Illustration shows camshafts removed.

Secure bolts (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 504

Tighten the screw (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Assemble engine.

11 12 101 REPLACING CYLINDER HEAD GASKET (N12)

Special tools required

1. 11 4 470

Necessary preliminary tasks

1. Remove cylinder head .

Remove remnants of oil and dirt from pocket holes (1).

Note. Illustration shows N52.

Scheme 505

Note identification marking on head gasket.

Gasket (1) is a sheet-metal gasket

Scheme 506

Check adapter sleeves (1) for damage and firm seating.

Lay cylinder head gasket on engine block.

Scheme 507

Note. Check cylinder head for deviation from flatness. Check cylinder head for water leaks. Refer to 11 12 729 CHECKING CYLINDER HEAD FOR WATER LEAKS (N12) .

Assemble engine.

11 12 719 RESURFACING CYLINDER HEAD SEALING FACE (N12)

Necessary preliminary tasks

1. Remove cylinder head.
2. Remove exhaust camshaft.
3. Remove intermediate lever on inlet side.

Check evenness of cylinder head sealing faces with a standard straight-edge (1).

Note. Max. deviation from level (longitudinal) 0.10 mm Picture show N52.

Scheme 508

Check evenness of cylinder head sealing faces with a standard straight-edge (1).

Note. Max. deviation from level (transversal) 0.05 mm Picture show N52.

Scheme 509

Check cylinder head for water leaks. Refer to 11 12 729 CHECKING CYLINDER HEAD FOR WATER LEAKS (N12) .

Assemble engine.

11 12 729 CHECKING CYLINDER HEAD FOR WATER LEAKS (N12)

Special tools required

1. 11 9 521
2. 11 9 522
3. 11 9 523

Necessary preliminary tasks

1. Remove cylinder head.
2. Disassemble cylinder head.

Install special tool 11 9 521 with special tool 11 9 523 .

Installation

Install special tool 11 9 521 so that all water ducts are sealed.

Scheme 510

Secure special tool 11 9 523 to 25 Nm .

Scheme 511

Screw special tool 11 9 522 into place with existing screws (1 and 3) of coolant thermostat.

Sealing flange must rest flat.

Note. Compressed air at valve (2) must not exceed 3 bar . Heat cylinder head to 60°. Visually check for bubble formation in a water bath.

Scheme 512

Assemble engine.

11 13 000 REMOVING AND INSTALLING, SEALING OR REPLACING OIL SUMP (N12)

Special tools required

1. 11 4 470
2. 11 9 581
3. 11 9 582

Necessary preliminary tasks

1. Drain engine oil.

Release oil sump bolts in area of line (1).

Tightening torque: Refer to ENGINE - TIGHTENING TORQUES .

Scheme 513

Release screw (1) over exhaust manifold with special tools 11 9 582 and 11 9 581 .

Tightening torque: Refer to ENGINE - TIGHTENING TORQUES .

Scheme 514

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

Scheme 515

Remove protruding or surplus sealing beads (1) with a suitable tool.

Installation

Do not use liquid seal.

A metal substrate gasket is available for repairs (see BMW Parts Service).

Scheme 516

Assemble engine.

11 14 005 REPLACING FRONT CRANKSHAFT RADIAL SEAL (N12)

Special tools required

1. 11 9 601
2. 11 9 602
3. 11 9 603

Necessary preliminary tasks

1. Remove vibration damper.
2. Remove A/C line from compressor.

If the central bolt is released, the sprocket wheels of the timing chain and the oil pump will no longer be non-positively connected to the crankshaft. The camshafts to the crankshaft can warp (risk of damage) .

Scheme 517

Drive PTFE ring inwards with a drift (1) until PTFE ring tilts outwards at bottom.

Scheme 518

Secure special tool 11 9 601 with screws (1) to crankshaft to 15 Nm.

Scheme 519

Installation

Apply a light coating of oil to special tool 11 9 601 .

Position PTFE ring (2) with supporting ring (1) on special tool 11 9 601 .

Push PTFE ring (2) over supporting ring (1) in direction of arrow up to crankcase.

Scheme 520

Remove supporting ring from special tool 11 9 601 .

Note. Supporting ring is no longer needed.

Scheme 521

Draw in PTFE ring with special tool 11 9 602 in conjunction with special tool 11 9 603 until flush.

Scheme 522

Assemble engine.

11 14 151 REPLACING CRANKSHAFT RADIAL SEAL (N12)

Special tools required

1. 11 9 611
2. 11 9 612
3. 11 9 613

Necessary preliminary tasks

1. Remove transmission.
2. Remove flywheel.

Brake off PTFE ring (2) with a drift (1).

Scheme 523

Secure special tool 11 9 611 with supplied screws (1) to crankshaft.

Scheme 524

Position PTFE ring (1) with supporting ring (2) on special tool 11 9 611 .

Push PTFE ring (1) in direction of arrow over supporting ring (2) onto crankshaft.

Scheme 525

Attach special tool 11 9 612 .

Draw in PTFE ring with special tool 11 9 613 .

Scheme 526

Screw in special tool 11 9 612 up to engine block.

Scheme 527

Assemble engine.

11 21 500 REPLACING CRANKSHAFT (N12)

Special tools required

1. 00 9 120
2. 11 4 471
3. 11 4 472
4. 11 6 251
5. 11 6 252
6. 23 1 240

Necessary preliminary tasks

1. Remove engine.
2. Mount engine on assembly stand.
3. Remove vibration damper.
4. Removing oil pan.
5. Remove oil pump.
6. Remove timing chain.
7. Remove cylinder head.
8. Remove flywheel.

Release screws (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Remove oil deflector (2).

Remove all pistons.

Scheme 528

Drive out cover plates (1) with a cross-chisel (2).

Scheme 529

Release screws (26 to 11).

Release screws (10 to 1).

Scheme 530

Release crankcase lower half in direction of arrow with a regular screwdriver (2) and an open-end wrench (1).

Scheme 531

Remove both radial shaft seals (1).

Scheme 532

Remove crankshaft (1).

Remove main bearing shells, replace if necessary.

Scheme 533

Clean sealing faces with special tools 11 4 471 and 11 4 472 .

Scheme 534

Check guide sleeves (1) for damage and correct seating.

Scheme 535

Apply sealing bead (1) to crankcase lower half.

Scheme 536

Apply sealing bead (1) to crankcase upper half.

Apply a light coating of engine oil to bearings.

Scheme 537

Insert crankshaft (1).

Lubricate all bearings from 1 to 5 with engine oil.

Install crankcase lower half.

Scheme 538

Tighten bolts (1 to 10).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Tighten bolts (11 to 26).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Tighten bolts exclusively with special tool 00 9 120 .

Scheme 539

Apply a thin coating of Loctite 273 to cover sleeve (1) in area (2).

Scheme 540

Drive cover sleeves firmly home with special tool 23 1 240 .

Scheme 541

Determine crankshaft axial clearance.

Attach special tool 11 6 252 with magnet.

Set special tool 11 6 251 to zero.

Press crankshaft in direction of rotation up to stop.

Scheme 542

Replace radial shaft seal at front.

Replace radial shaft seal at rear.

Assemble engine.

11 21 531 REPLACING ALL CRANKSHAFT MAIN BEARINGS (N12)

Special tools required

1. 11 4 470

Necessary preliminary tasks

1. Remove crankshaft .

Installation

Bearing shell (1) with lubricant groove must be fitted in crankcase upper section.

Bearing shell (2) without lubricant groove must be fitted in crankcase lower section (bedplate).

Scheme 543

Bearings (1 to 5).

Bearing (2) is a guide bearing.

Clean sealing faces with special tool 11 4 470 only.

Scheme 544

Insert guide rings (1) in crankcase at bearing block (2) with groove facing outwards.

If necessary, attach with engine oil to crankcase.

Scheme 545

Bearings (1 to 5).

Clean sealing faces with special tool 11 4 470 only.

Scheme 546

Bearing classification on crankcase upper half

Bearing allocation 1-5: the designations on the crankcase and crankshaft are always required.

Refer to the table for the color code.

Example

Bearing 1. Letter P

Bearing 2. Letter K

Bearing 3. Letter I

Bearing 4. Letter N

Bearing 5. Letter N

Scheme 547

Bearing classification on crankcase upper half

Bearing allocation 1-5: the designations on the crankcase and crankshaft are always required.

Refer to the table for the color code.

Example

Bearing 1. Letter T

Bearing 2. Letter Q

Bearing 3. Letter Q

Bearing 4. Letter R

Bearing 5. Letter R

Scheme 548

CRANKSHAFT BEARING COLOR CHART

Crankshaft bearing colors

BL= Blue.

SW= Black.

Gr= Green.

Ge Yellow.

Or Orange.

Bearing classification on crankcase lower half

Bearing allocation 1-5: the designations on the crankcase and crankshaft are always required.

Refer to the table for the color code.

Example

Bearing 1. Letter P

Bearing 2. Letter K

Bearing 3. Letter I

Bearing 4. Letter N

Bearing 5. Letter N

Bearing classification on crankcase lower half

Bearing allocation 1-5: the designations on the crankcase and crankshaft are always required.

Refer to the table for the color code.

Example

Bearing 1. Letter T

Bearing 2. Letter Q

Bearing 3. Letter Q

Bearing 4. Letter R

Bearing 5. Letter R

CRANKSHAFT BEARING COLOR CHART

Example: Crankcase upper half

Combining the dots of the designations of the crankshaft and crankcase produces the following color combinations.

Bearing 1: The letters (P and T) produce in the crankcase upper half the color Ge= Yellow with lubricant groove.

Bearing 2: K and Q= Ge= Yellow.

Bearing 3: I and Q= Ge= Yellow.

Bearing 4: N and R= Gr= Green.

Bearing 5: N and R= Gr= Green.

Example: Crankcase lower half

Combining the dots of the designations of the crankcase and crankshaft produces the following color combinations.

Bearing 1: The letters P. and T. produce in the crankcase lower half the color Gr= Green without lubricant groove.

Bearing 2: K and Q= Gr= Green.

Bearing 3: I and Q= Gr= Green.

Bearing 4: N and R= Gr= Green.

Bearing 5: N and R= Gr= Green.

Install crankcase lower section.

Assemble engine.

11 22 500 REMOVING AND INSTALLING OR REPLACING FLYWHEEL (N12)

Special tools required

1. 11 9 590

Necessary preliminary tasks

1. Remove transmission.
2. Remove clutch.

Lock flywheel with special tool 11 9 590 .

Flywheel for automatic transmission.

Release flywheel bolts (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Installation

Flywheel (1) is secured with an alignment pin.

Fit new flywheel screws.

Clean crankshaft thread for flywheel screws.

Scheme 549

Flywheel for manual gearbox.

Flywheel with and without dual-mass: release bolts (1).

Installation

Flywheel is secured with a dowel pin.

Fit new flywheel screws.

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 550

Installation

Sensor gear (1) is loose on crankshaft and is first secured to flywheel.

Dowel pin (2) for securing sensor gear/flywheel.

Scheme 551

Assemble engine.

Special tools required

1. 11 9 590

Necessary preliminary tasks

1. Remove transmission.
2. Remove clutch.

Lock flywheel with special tool 11 9 590 .

Flywheel for automatic transmission.

Release flywheel bolts (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Installation

Flywheel (1) is secured with an alignment pin.

Fit new flywheel screws.

Clean crankshaft thread for flywheel screws.

Flywheel for manual gearbox.

Flywheel with and without dual-mass: release bolts (1).

Installation

Flywheel is secured with a dowel pin.

Fit new flywheel screws.

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Installation

Sensor gear (1) is loose on crankshaft and is first secured to flywheel.

Dowel pin (2) for securing sensor gear/flywheel.

Assemble engine.

11 24 571 REPLACING CONROD BEARINGS (N12)

Necessary preliminary tasks

1. Remove all pistons.

Install new conrod bearing shells.

Insert conrod bearing shells (1 and 2).

Scheme 552

Install all pistons with conrods.

Assemble engine.

11 25 530 REMOVING AND INSTALLING/REPLACING ALL PISTONS (N12)

Special tools required

1. 00 9 120
2. 11 9 620
3. 11 9 670

Necessary preliminary tasks

1. Remove engine.
2. Mount engine on assembly stand.
3. Remove intake air manifold.
4. Remove cylinder head.
5. Remove engine oil sump.
6. Remove oil pump.

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

Note. Illustrations show N46.

Scheme 553

Note. Mark all pistons and conrods with a pen prior to removing.

Example N14

Direction of arrow (1) points to camshaft drive.

Cylinder allocation (2) per cylinder.

Scheme 554

Note. Mark all pistons and conrods with a pen prior to removing.

Example

Mark cylinder allocation (1) per cylinder.

Direction of arrow (2) points to camshaft drive.

Scheme 555

Release connecting rod bolts (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Remove conrod bearing cap.

Scheme 556

Attach special tool 11 9 620 in conrod big end.

Press out connecting rod and piston to cylinder head side.

Scheme 557

Lever out piston pin circlip with a screwdriver in direction of arrow.

Scheme 558

If necessary, replace connecting rods.

Installation

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

Scheme 559

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 gudgeon pin.

Piston diameter at measuring point A.

Scheme 560

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

Diameter of cylinder bore.

Piston installation clearance.

Total permissible wear tolerance.

If necessary, replace piston.

Scheme 561

Install all piston rings.

Install all bearing shells.

Coat piston and piston rings with oil.

Pre-install piston in special tool 11 9 670 .

Screw special tool 11 9 620 into conrod.

Installation

Check protective lugs on special tool 11 9 620 for correct position and damage.

Scheme 562

Insert piston with connecting rod in cylinder.

Insert piston (1) so that arrow on piston crown points to camshaft drive.

If reusing the pistons, assign cylinder allocation (2) to correct cylinder.

Press in piston with special tool 11 9 670 .

Scheme 563

Mixing them up or incorrectly fitting the conrod bearing cap on the big end will result in engine damage .

Both pairing letters (2) must be together on one side.

Scheme 564

Apply a light coat of oil to crank pin.

Assemble connecting rod and crank pin.

Remove special tool 11 9 620 .

Fit bearing caps (2) so that pairing letters match up.

Check cylinder identification markings (1).

Direction of arrow (2) points to camshaft drive.

Install new connecting rod bolts (1).

Carry out torsion angle tightening of conrods with special tool 00 9 120 .

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Assemble engine.

11 25 671 REPLACING PISTON RINGS ON ALL PISTONS (N12)

Special tools required

1. 11 9 670

Necessary preliminary tasks

1. Remove all pistons.

Measuring axial clearance of piston rings in piston ring groove.

Technical Data.

Note. It is not possible to measure the axial clearance of the oil scraper rings.

Scheme 565

Remove compression ring and stepped ring upwards with piston ring pliers.

Oil scraper ring comprises two steel band rings and a support spring.

Note. Oil scraper ring cannot be removed with piston ring pliers. Put aside piston rings in correct sequence and installation position. It might not be possible to find the identification on used piston rings.

Installation

New pistons may only be installed together with new piston rings.

Scheme 566

Determine gap with a feeler gauge.

Scheme 567

Installation

Piston rings with "TOP" identification must point to piston crown.

Scheme 568

Installation

Piston rings with "TOP" identification must point to piston crown.

1. Plain compression ring
2. Taper face ring
3. Two-part oil scraper ring

Scheme 569

Note. The oil control ring comprises a steel band ring (1) and a support spring (2).

Installation

Insert support spring (2) in piston ring groove and then fit steel band ring (1) so that end faces point to each other.

Scheme 570

Offset the contact points (1) of the piston rings by approx. 120° to each other but do not position above the piston pin boss. Coat special tool 11 9 670 with sufficient engine oil. Risk of damage to piston rings!

Scheme 571

Assemble engine.

11 28 010 REPLACING ALTERNATOR DRIVE BELT (N12)

Necessary preliminary tasks

1. Remove right wheel arch cover
2. Remove right headlight
3. Remove lock bridge

Bring belt tensioner (1) with wrench (2) into assembly position.

Secure assembly position of belt tensioner (1) by sliding locating pin (3) in direction of arrow.

Remove drive belt (4) from alternator.

Note. For reasons of clarity, illustration and text show front wall removed.

Scheme 572

Move friction wheel (2) into servicing position.

In order to release the frictional connection between crankshaft and coolant pump, it is necessary to move the friction gear (2) into the servicing position.

Firmly pull handle (1) in direction of arrow until friction gear (2) is separated from belt pulley.

Scheme 573

To secure friction gear in servicing position, suspend pull cable (1) on housing (2).

Scheme 574

Assemble engine.

Installation

Check that drive belt for is in correct installation position - risk of damage .

11 28 012 REPLACING DRIVE BELT (WITHOUT A/C SYSTEM)

Special tools required

1. 11 9 680

Necessary preliminary tasks

1. Remove right wheel arch line.

Cut through ribbed V-belt with a suitable tool (2).

Scheme 575

Position special tool 11 9 680 on vibration damper (see arrow).

Scheme 576

Attach special tool 11 9 680 in direction of arrow and slide further in direction of arrow.

Scheme 577

Move special tool 11 9 680 on vibration damper into assembly position.

Scheme 578

Place ribbed V-belt (1) on alternator (2).

Scheme 579

Place ribbed V-belt (1) in direction of arrow on vibration damper.

Scheme 580

Turn vibration damper in direction of arrow.

Press ribbed V-belt (1) inwards by hand (see arrow).

Scheme 581

Turn vibration damper until drive belt on alternator and on vibration damper has fully jumped.

Remove special tool 11 9 680 from vibration damper.

Check correct seating of drive belt.

Scheme 582

Add final details to vehicle.

11 28 020 REPLACING TENSIONING DEVICE FOR ALTERNATOR DRIVE BELT (N12)

Necessary preliminary tasks

1. Bring front panel into service position.
2. Disconnect lambda oxygen sensor cable.

Pretension tensioning device (1) with tool (2) in direction of arrow.

Press in locking pin (3) in direction of arrow and hold.

Slowly release tool (2) and secure in position.

Note. Locking pin (3) holds tensioning device (1) at pretension.

Release screws (2).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Remove tensioning device (3).

Scheme 583

Installation

Lever tensioning device (1) with tool (2) in direction of arrow.

Locking pin (3) is pretensioned with a spring and is automatically relieved during unlocking.

Ensure drive belt is in correct installation position.

Assemble engine.

11 28 035 REMOVING AND INSTALLING/REPLACING FRICTION GEAR (N12)

Special tools required

1. 11 9 581
2. 11 9 583

Necessary preliminary tasks

1. Remove right wheel arch cover

Pull out friction gear with mechanical release (3) in direction of arrow and lock on locking hook.

Friction gear (1) lifts mechanically off belt drive.

Disconnect plug connection (2) on friction gear.

Note. Picture shows friction gear removed.

Scheme 584

Move friction gear (2) into servicing position.

To secure friction gear in servicing position, suspend pull cable (1) on housing (2).

Secure belt pulley of water pump with an oil filter band (1).

Release bolts (2) with special tools 11 9 581 and 11 9 583 .

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 585

Release bolts (1) with special tools 11 9 583 and 11 9 581 .

Scheme 586

Remove friction gear (1) towards bottom.

Disconnect plug connection (2).

Scheme 587

Assemble engine.

Installation

Check cable routing for correct installation position - risk of damage .

Check function of DME.

11 31 005 CHECKING CAMSHAFT TIMING

Special tools required

1. 11 9 540
2. 11 9 590

Necessary preliminary tasks

1. Remove cylinder head cover.
2. Remove front splash guard.

Rotate crankshaft at central bolt.

Position crankshaft with special tool 11 9 590 .

Do not remove special tool 11 9 590 during repair work.

Both camshafts are in the correct installation position when the designation (IN) for inlet camshaft points upwards.

In the case of the exhaust camshaft, the designation EX must point upwards.

Scheme 588

Position of exhaust camshaft (A) points at an angle to the right in an upper outward direction

Scheme 589

Position of inlet camshaft (E) points at an angle to the left in an upper outward direction

Scheme 590

Position special tool 11 9 540 (exhaust) on direction of exhaust camshaft and secure with a bolt (1).

Scheme 591

Position special tool 11 9 540 (inlet) on direction of inlet camshaft and secure with a bolts (1 and 2).

Scheme 592

If necessary, adjust valve timing.

Assemble engine.

11 31 025 REMOVING AND INSTALLING/REPLACING INLET CAMSHAFT (N12)

Special tools required

1. 11 4 481
2. 11 9 551

Necessary preliminary tasks

1. Remove cylinder head cover.
2. Remove adjusting unit for inlet camshaft.
3. Remove intermediate lever.
4. Remove exhaust camshaft.

Scheme 593

Bearing cap (1) marked 5 is a thrust bearing.

Release screws of bearing caps (1 to 5).

Set all bearing caps down in special tool 11 4 481 in a tidy and orderly fashion.

Remove camshaft (6).

Installation

Clean all bearing points and lubricate with oil.

Check plain compression rings for damage.

Scheme 594

If necessary, replace plain compression rings (1).

The plain compression rings have catches at the joint.

Press plain compression rings (1) apart upwards and downwards and removed towards front.

Make sure plain compression rings (1) can move freely.

Scheme 595

Insert camshaft (E) so that IN marking points upwards.

Position inlet camshaft (E) so that cams point upwards at an angle.

Attach special tool 11 9 551 to twin surface.

Make sure plain compression rings cable can move freely.

All bearing caps are identified from 5 to 10.

Pay attention to pairing letters (1).

Scheme 596

Tighten bearing caps from inside outwards.

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Adjust valve timing.

Assemble engine.

11 31 028 REMOVING AND INSTALLING/REPLACING EXHAUST CAMSHAFT (N12)

Special tools required

1. 11 4 480
2. 11 9 000
3. 11 9 590
4. 11 9 650
5. 11 9 652

Necessary preliminary tasks

1. Remove cylinder head cover.
2. Remove vacuum pump.
3. Remove exhaust adjusting unit for exhaust camshaft.
4. Release central bolt of inlet adjustment unit.

Secure special tool 11 9 650 on cylinder head with screws 1 in spark plug holes.

Scheme 597

Release bearing cap screws from 10 to 1.

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

Scheme 598

Check plain compression rings (1) for damage and replace if necessary.

Plain compression rings (1) are engaged at joint.

Press plain compression rings (1) apart upwards and downwards and removed towards front.

Removed cylinder head

When using special tool 11 9 000 , it will be necessary to remove the aluminum profile insert.

Installation

Before installing exhaust camshaft, make sure roller rocker arm is correctly seated HVCA element and valve.

Scheme 599

Installation

Lubricate all bearing points with engine oil.

Insert camshaft (1).

Pay attention to installation position (2).

Scheme 600

Designation (EX) on exhaust camshaft points upwards.

Make sure plain compression rings (1) can move freely.

Align plain compressing rings (1) in downward direction.

Lubricate all bearing points (2) with engine oil.

Scheme 601

Secure special tool 11 9 650 on cylinder head with screws 1 in spark plug holes.

Pretension camshaft (2).

Fit and secure bearing bridges.

Bearing bridges, allocation of exhaust camshaft from (0 to 4).

Scheme 602

Fit all bearing bridges from 0 to 4.

Secure screws in sequence (1 to 10).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Note. Shown without special tool 11 9 650 for purposes of clarity.

Adjust valve timing.

Assemble engine.

11 31 051 REPLACING TIMING CHAIN (N14)

Special tools required

1. 00 9 120
2. 11 9 280
3. 11 9 540
4. 11 9 590

Necessary preliminary tasks

1. Remove cylinder head cover.
2. Remove all spark plugs.
3. Remove vibration damper.
4. Remove chain tensioner.
5. Remove both VANOS adjustment units.
6. Remove PTFE ring at front.
7. Remove belt tensioner.

Position crankshaft with special tool 11 9 590 .

Do not remove special tool 11 9 590 during repair work.

Do not remove special tool 11 9 540 .

Fit special tool 11 9 280 on hub for vibration damper with screws (2).

Scheme 603

Release central bolt in direction of arrow.

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 604

Release bearing pins (1 and 2).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 605

Remove hub (3) towards front.

Remove chain module with timing chain.

Using a hook (2), pull oil pump chain (1) upwards.

Scheme 606

Sprocket wheel (1) of timing chain.

Sprocket wheel (2) of oil pump.

Scheme 607

Secure chain module (1) with rubber (3) to facilitate assembly.

Pull timing chain (2) upwards until sprocket wheel (4) rests against chain guide (1).

Install timing chain (2) and sprocket wheel (4) in this position.

Installation

Always keep timing chain (2) tensioned; it is possible for timing chain (2) to jam on chain module (1).

Scheme 608

Installation position of both sprocket wheels.

Sprocket wheel (1) of oil pump.

Guide rail (2) of timing chain.

Hub (3) on crankshaft.

Sprocket wheel (4) of timing chain.

Scheme 609

Attach oil pump sprocket wheel (2) in direction of arrow to crankshaft (1).

Insert chain module with timing chain and secure.

Attach crankshaft hub.

Screw in central bolt.

Scheme 610

Remove special tool 11 9 280 from hub.

Secure central bolt with special tool 00 9 120 .

Scheme 611

Install VANOS adjustment units.

Crank engine twice.

Check timing.

Install PTFE ring.

Assemble engine.

11 31 090 INSTALLING AND REMOVING/REPLACING CHAIN TENSIONER PISTON (N12)

Necessary preliminary tasks

1. Remove throttle valves.

Release chain tensioner (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Installation

Replace sealing ring.

Scheme 612

If the chain tensioner is reused, its oil chamber must be drained. Place chain tensioner on a level working surface and slowly compress.

Repeat procedure twice.

Scheme 613

Assemble engine.

11 31 505 ADJUSTING CAMSHAFT TIMING (N12)

Special tools required

1. 00 9 120
2. 00 9 250
3. 11 9 340
4. 11 9 450
5. 11 9 540
6. 11 9 590
7. 32 2 100

Necessary preliminary tasks

1. Remove cylinder head cover.
2. Check timing.

Rotate crankshaft at central bolt.

Slide in special tool 11 9 590 in direction of arrow and block crankshaft.

To open central bolt, mount special tool 11 9 540 on camshaft.

If the setting gauges cannot be positioned, grip the camshaft with an open-end wrench to release the central bolt.

Release chain tensioner (have a cleaning cloth ready).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

To open central bolts (1 and 2), mount special tool 11 9 540 on camshafts.

Release central bolts (1 and 2).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 614

The designations for the inlet camshaft (IN) and exhaust camshaft (EX) point upwards.

Both camshafts (inlet and exhaust) have three machined surfaces to enable special tool 11 9 450 to be mounted.

The fourth surface is not machined and is crescent-shaped - it must point downwards.

Position of exhaust camshaft (EX) points at an angle to the right in an upper outward direction.

Position of inlet camshaft (E) points at an angle to the left in an upper outward direction.

Rotate exhaust camshaft with special tool 32 2 100 in direction of arrow.

Scheme 615

Pretension camshaft with special tool 32 2 100 .

Attach special tool 11 9 540 (exhaust side) to direction and secure with bolt (1).

Scheme 616

Attach special tool 11 9 540 (inlet side) to direction and secure with bolts (1 and 2).

Screw special tool 11 9 340 into cylinder head.

Pretension timing chain with special tool 00 9 250 to 0.6 Nm .

Scheme 617

Secure central bolt (1) with special tool 00 9 120 or an electronic torque wrench.

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 618

Secure central bolt (1) with special tool 00 9 120 or an electronic torque wrench.

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 619

Remove all special tools.

Assemble engine.

11 33 050 REMOVING AND INSTALLING/REPLACING ALL CAM FOLLOWERS (N12)

Special tools required

1. 11 4 480

Necessary preliminary tasks

1. Remove cylinder head cover.
2. Remove intermediate lever.
3. Remove exhaust camshaft.

Scheme 620

Remove HVCA element in direction of arrow.

Installation

If the HVCA elements are to be reused, set them down in special tool 11 4 480 in a tidy and orderly fashion with the roller cam followers.

Scheme 621

Detach roller cam followers (1) from HVCA element and remove.

Set all roller cam followers down in special tool 11 4 480 in a tidy and orderly fashion.

Installation

Before installing exhaust camshaft and intermediate lever, make sure roller cam followers are correctly seated (see arrows).

Assemble engine.

Check function of DME; if necessary, readjust uniform mixture distribution.

11 34 552 REMOVING AND INSTALLING OR REPLACING ALL VALVES (N12)

Special tools required

1. 11 4 480

Necessary preliminary tasks

1. Remove cylinder head.
2. Remove intermediate lever.
3. Remove eccentric shaft.
4. Remove inlet camshaft.
5. Remove exhaust camshaft.
6. Remove roller cam follower.
7. Remove valve springs.
8. Remove valve stem seals.

Arrangement

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

If the valves are to be reused, set then down in special tool 11 4 480 in a tidy and orderly fashion.

Scheme 622

Assemble engine.

Check function of DME; if necessary, readjust uniform mixture distribution.

11 34 560 REPLACING ALL VALVE STEM SEALS (N52)

Special tools required

1. 11 1 480
2. 11 6 380

Necessary preliminary tasks

1. Remove cylinder head.
2. Remove intermediate lever.
3. Remove eccentric shaft.
4. Remove inlet camshaft.
5. Remove exhaust camshaft.
6. Remove roller cam follower.

Firmly press special tool 11 1 480 onto old valve stem seals (1).

Detach valve stem seal from valve stem by turning and simultaneously pulling special tool 11 1 480 .

Scheme 623

Installation

Insert all valves .

Fit the mounting sleeves (plastic sleeves) supplied in the spare part on the valve stem end

Lubricate mounting sleeve.

Press on valve stem seal by hand with special tool 11 6 380 as far as it will go.

Scheme 624

Assemble engine.

11 34 715 REPLACING ALL VALVE SPRINGS (N12)

Special tools required

1. 11 4 480
2. 11 9 000
3. 11 9 006
4. 11 9 007
5. 11 9 017

Necessary preliminary tasks

1. Remove cylinder head.
2. Remove exhaust camshaft.
3. Remove intermediate lever.
4. Remove inlet camshaft.
5. Remove roller cam follower.

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

Scheme 625

Prepare special tool 11 9 007 on special tool 11 9 006 .

Scheme 626

Align special tool 11 9 006.

Lock eccentrics (1) on special tool 11 9 000 in direction of arrow.

Scheme 627

Press down valve spring and spring retainer (1) with special tool 11 9 017 .

Scheme 628

Remove valve tapers with a magnet.

Remove valve spring and spring retainer.

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

Scheme 629

Color marking (1) is normally on lower end of valve spring.

Only the diameter pointing to the spring retainer at the bottom is required for correct installation of the valve spring.

Scheme 630

Arrangement

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

Assemble engine.

Check function of DME; if necessary, readjust uniform mixture distribution.

11 36 655 REMOVING AND INSTALLING/REPLACING BOTH SOLENOID VALVES (N12)

Necessary preliminary tasks

1. Remove acoustic cover

Disconnect plug connection for solenoid valve (3) - inlet.

Release screw (1).

Remove solenoid valve (2) for inlet side.

Scheme 631

Disconnect plug connection for solenoid valve - exhaust.

Release screw (2).

Remove solenoid valve (1) for exhaust side.

Scheme 632

Installation

Replace sealing rings on solenoid valves.

Scheme 633

Assemble engine.

Check function of DME.

11 37 005 REMOVING AND INSTALLING/REPLACING ECCENTRIC SHAFT (N12)

Special tools required

1. 11 4 481

Necessary preliminary tasks

1. Remove cylinder head cover.
2. Remove intermediate lever.
3. Remove inlet camshaft.

Release screw (2) on magnet wheel (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 634

Installation

Pay attention to journal and groove on intermediate shaft and magnet wheel.

Scheme 635

Scheme 636

Adjust eccentric shaft to minimum lift (1).

Scheme 637

Release screws on all bearing caps (1).

Scheme 638

All bearing caps are marked with numbers from (6 to 10); set down in neat order in special tool 11 4 481 .

Scheme 639

Remove intermediate shaft (1).

Scheme 640

Check all needle bearings (3) of eccentric shaft (1) for ease of movement.

Scheme 641

Bearing cap number 10 is provided with a stop.

Lubricate all bearing caps with engine oil.

All bearing caps (1) are identified with numbers from (6 to 10).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Adjust eccentric shaft minimum lift.

Check eccentric shaft for ease of movement.

Assemble engine.

11 37 010 REMOVING AND INSTALLING/REPLACING INTERMEDIATE LEVER (N12)

Special tools required

1. 11 4 480
2. 11 5 571
3. 11 9 571
4. 11 9 572
5. 11 9 573

Necessary preliminary tasks

1. Remove cylinder head cover.

Scheme 642

Position special tool 11 9 571 on bearing block of balancing shaft so that it rests on intermediate shaft (see arrow).

If necessary, set eccentric shaft (1) to minimum lift (2).

Scheme 643

Clamp return spring with knurled screw (1).

Scheme 644

Make sure return spring is correctly seated on special tool 11 9 571 (see arrow).

Scheme 645

When special tool 11 9 571 is correctly positioned, return spring (2) can be pressed back with lever (1).

Scheme 646

Press lever (1) in direction of arrow on special tool 11 9 571 until locking hook (2) engages on special tool 11 9 571 .

Scheme 647

Locking hook (1) must engage on special tool 11 9 571 (see arrow).

Scheme 648

Release screw (1).

Scheme 649

Prepare special tool 11 9 572 on a vice (1).

Scheme 650

Feed out special tool 11 9 571 in return spring (1).

Scheme 651

Set down special tool 11 9 571 on special tool 11 9 572 (see arrow).

Scheme 652

Release locking hook (1) on special tool 11 9 571 .

Release lever (2) in direction of arrow.

Scheme 653

Release knurled screw (1) in direction of arrow.

Remove return spring (2).

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

Scheme 654

Release bolt (2).

Release centering bolt (1).

Remove locating plate and set down on special tool 11 4 480 in a tidy and orderly fashion.

Scheme 655

Note. Screw (1) Setscrew (2)

Installation

Observe screwing sequence

Scheme 656

Remove roller cam follower (3) towards top and set down on special tool 11 4 480 in a tidy and orderly fashion.

Installation

Uniform distribution must not be changed.

Scheme 657

All roller cam followers are classified.

Values of 0 to 5 are installed.

Note. A uniform distribution can only be calculated with the diagnosis tester.

Scheme 658

Installation

Installation of roller cam followers.

Position torsion spring (1) on special tool 11 9 571 (see arrows) and clamp with knurled screw.

Scheme 659

Press torsion spring (1) in direction of arrow and position with lever of special tool 11 9 571 .

Scheme 660

Pretension spiral-wound spring (1) with special tool 11 9 571 in direction of arrow.

Scheme 661

Locking hook (1) must engage on special tool 11 9 571 (see arrow).

Insert intermediate levers (3).

Installation

Make sure roller cam followers (2) are in correct installation position.

Install guide block.

Insert setscrew (1).

Insert screw (2).

Join screws (1 and 2) to 5 Nm.

Release screws (1 and 2) back by 90°.

Pretension guide block (1) with special tool 11 9 573 .

Secure setscrews of guide block (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Secure screw on guide block (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 662

Feed in return spring (1) with special tool 11 5 571 and position.

Secure screw (1) of return spring.

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Installation

Insert return spring (2) in intermediate lever (1) (see arrow).

Check roller cam follow (3) again to ensure correct installation position.

Scheme 663

Remove all special tools.

Assemble engine.

11 37 020 REMOVING AND INSTALLING/REPLACING POSITIONING MOTOR FOR ECCENTRIC SHAFT (N12)

Necessary preliminary tasks

1. Remove acoustic cover.

Disconnect plug connection (2) on servodrive.

Pull off engine wiring harness at retaining clip (1) from servodrive.

Scheme 664

Release screws (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Installation

Replace seal.

Scheme 665

Turn screwdriver (1) counterclockwise in direction of arrow and relieve tension on intermediate shaft.

Note. Do not rotate shaft too far up to maximum to end stop.

Remove servodrive.

Installation

Insert servodrive with screwdriver (2).

Assemble engine.

Scheme 666

Check function of DME.

11 37 030 REMOVING AND INSTALLING/REPLACING ECCENTRIC SHAFT SENSOR (N12)

Necessary preliminary tasks

1. Check function of DME.

Disconnect plug connection (1).

Release screws (2).

Scheme 667

Assemble engine.

11 40 000 CHECKING ENGINE OIL PRESSURE (N12)

Special tools required

1. 11 7 020
2. 11 9 560
3. 13 3 061
4. 13 3 063
5. 13 6 051
6. 13 6 054

Disconnect plug connection (1) on oil pressure switch.

Scheme 668

Release oil pressure switch (1) with special tool 11 7 020 .

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Installation

Replace sealing ring.

Scheme 669

Screw in special tool 11 9 560 with sealing ring on cylinder head.

Secure pressure gauge connection 13 3 063 to special tool 11 9 560 .

Scheme 670

Check engine oil pressure with diagnosis tester.

Connect special tools 11 9 560 / 13 6 054 and 13 6 051 .

Check engine oil pressure with pressure gauge.

Connect special tools 11 9 560 / 13 3 063 and 13 3 061 .

Start engine and check engine oil pressure.

Scheme 671

Assemble engine.

11 41 000 REMOVING AND INSTALLING OIL PUMP (N12)

Necessary preliminary tasks

1. Removing oil pan.

Pull off cover (1) in direction of arrow.

Installation

Replace cover (1).

Scheme 672

Release screw (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Grip central bolt (2) to release central bolt (1).

Scheme 673

Release screws (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 674

Assemble engine.

11 42 020 REMOVING AND INSTALLING/REPLACING MAIN FLOW OIL FILTER (N12)

Necessary preliminary tasks

1. Unfasten oil filter cover.
2. Remove exhaust manifold.

Release screws (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 675

Replace seal (1).

Scheme 676

Assemble engine.

11 43 000 REMOVING AND INSTALLING/REPLACING GUIDE TUBE FOR DIPSTICK (N12)

Necessary preliminary tasks

1. Pull dipstick out of guide tube.

Release screw (2).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Pull dipstick (1) up in direction of arrow.

Installation

Replace O-ring.

Scheme 677

Assemble engine.

Check engine oil level, top up if necessary

11 51 000 REMOVING AND INSTALLING/REPLACING WATER PUMP (N12)

Recycling

Catch and dispose of drained coolant.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Remove friction gear.

Release screws (1).

Installation

Replace seal.

Clean sealing surfaces.

Scheme 678

Assemble engine.

Venting instructions must be observed without fail .

11 53 000 REMOVING AND INSTALLING/REPLACING COOLANT THERMOSTAT (N12)

Special tools required

1. 17 2 050

Recycling

Catch and dispose of drained coolant.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Drain coolant from radiator.

Release lock (1) on coolant pipe in direction of arrow.

Scheme 679

Disconnect plug connection (1) on coolant thermostat.

Scheme 680

Detach all coolant hoses from thermostat.

Note. Release metal hose clamps with special tool 17 2 050 .

Disconnect plug connection (1) on coolant temperature sensor.

Slacken nut (2).

Release screws (3).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 681

Installation

Replace seal (1).

Scheme 682

Assemble engine.

Vent cooling system and check for leaks.

11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (N12)

Necessary preliminary tasks

1. Remove suction filter housing.
2. Remove engine cover.

Unfasten engine wiring harness (1) on intake manifold.

Disconnect plug connection (2).

Disconnect plug connection (3) on tank vent valve.

Scheme 683

Disconnect plug connection (1).

Release tank vent valve (2).

Scheme 684

Disconnect plug connection (1) on solenoid valve.

Release engine breathers and hold to one side.

Slacken nut (2).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 685

Disconnect plug connection (1).

Unfasten engine wiring harness (2) on intake manifold.

Scheme 686

Release cable (1) at intake manifold holder.

Release screw (2).

Release screw (3).

Take off holder (4).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 687

Release screw (2).

Unscrew nuts (3).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 688

Installation

Replace all seals.

Assemble engine.

11 62 000 REMOVING AND INSTALLING, SEALING/REPLACING EXHAUST MANIFOLD (N12)

Necessary preliminary tasks

1. Move front end into assembly position.
2. Remove exhaust system.
3. Remove both lambda oxygen sensors.
4. Detach heat shield.

Release screws (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 689

Release all nuts (1).

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Feed out exhaust manifold (1) downwards.

Installation

Replace all seals.

Scheme 690

Assemble engine.

11 66 000 REMOVING AND INSTALLING/REPLACING VACUUM PUMP (N12)

Release vacuum connection to brake booster.

Release screws (1).

Pull out vacuum pump (2).

Scheme 691

Installation

Replace sealing ring (1).

Scheme 692

Assemble engine.

11 78 510 REMOVING AND INSTALLING/REPLACING CONTROL SENSOR (N12)

Special tools required

1. 11 7 020

Installation

If an oxygen sensor is to be reused, only apply a thin and uniform coat of Never Seez Compound (refer to BMW Parts Service) to thread.

The part of the oxygen control sensor which projects into the exhaust system branch (sensor ceramic) must not be cleaned or come into contact with lubricant.

Disconnect plug connection for control sensor.

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

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Note. For purposes of clarity, illustration shows and description refers to the removed engine.

Scheme 693

Assemble engine.

Check function of DME.

11 78 510 REMOVING AND INSTALLING/REPLACING LAMBDA CONTROL SENSORS (N12)

Special tools required

1. 11 7 020

Necessary preliminary tasks

1. Read fault memory.

Installation

If an oxygen sensor is to be reused, only apply a thin and uniform coat of Never Seez Compound (refer to BMW Parts Service) to thread.

The part of the oxygen control sensor which projects into the exhaust system branch (sensor ceramic) must not be cleaned or come into contact with lubricant.

Disconnect plug connection for lambda control sensor.

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

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 694

Assemble engine.

Check function of DME.

11 78 610 REMOVING AND INSTALLING/REPLACING LAMBDA MONITOR SENSORS (N12)

Special tools required

1. 11 7 030
2. 11 9 150

Necessary preliminary tasks

1. Read fault memory.

Installation

If an oxygen sensor is to be reused, only apply a thin and uniform coat of Never Seez Compound (refer to BMW Parts Service) to thread.

The part of the oxygen monitor sensor which projects into the exhaust system branch (sensor ceramic) must not be cleaned or come into contact with lubricant.

Disconnect plug connection for oxygen monitor sensor.

Release monitor sensor (1) with special tools 11 7 030 and 11 9 150 .

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 695

Assemble engine.

Check function of DME.

11 78 610 REMOVING AND INSTALLING/REPLACING MONITOR SENSOR (N12)

Special tools required

1. 11 7 020

Only perform these tasks after the exhaust system has cooled down.

Installation

If an oxygen sensor is to be reused, only apply a thin and uniform coat of Never Seez Compound (refer to BMW Parts Service) to thread.

The part of the oxygen monitor sensor which projects into the exhaust system branch (sensor ceramic) must not be cleaned or come into contact with lubricant.

Disconnect plug connection for monitor sensor.

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

Tightening torque: See ENGINE - TIGHTENING TORQUES .

Scheme 696

Assemble engine.

Check function of DME.