Honda Bmw 5 Service Manual

							
Cylinder Head Removal -- and lnstallati~i 
4 Cylinder head  bolt loosening sequence. 
- Using BMW special tool 11 2 250 or an  equivalent  tool, loos- 
en cylinder head bolts  in sequence.  Discard head  bolts. 
- Separate the cylinder head  from the block and remove  head. 
Evaluate head  as described  in 
116 Cylinder Head and Val- 
vetrain. 
Cylinder head, installing, M52 engine 
If the camshafts  were removed and installed  while the cylin- 
der  head  was off, a minimum waiting  time is required  after in- 
stalling  the camshafts.  When the camshafts are  removed, the 
hydraulic lifters can  expand. This expansion can  cause in- 
creased valve lift  when the camshafts are bolted  down, result- 
ing in open  valves. 
Camshaft  installation waiting  times 
68 F (20 C) and higher 4 minutes 
50.68 F (1 0-20 C) 11 minutes 
32-50 F (0-1 0 C) 30 minutes 
- Clean cylinder head  and gasket surfaces of cylinder  block 
and  all timing chain  covers. 
CAUTION- 
Do not use a metal  scraper  or wire  brush  to clean  the alumi- 
num  cylinder  head orpistons.  If necessary,  use a hard wood- 
en  orplastic  scraper. Also available  are abrasive discs  to be 
used  in conjunction  with an electric  drill. Be sure  to use  the 
correct disc for  the type of metal being  cleaned. 
- Remove all debris and fluids  from bolt holes and clean  with a 
thread  chaser. 
- Check gasket  surface of cylinder head  and cylinder  block for 
warpage using a straight  edge. 
NOTE- 
If the  cylinder  head has been  machined,  a special 0.3 mm 
thicker  gasket  should be installed.  The thicker 
gasket is avail- 
able from  an authorized 
BMW dealer.   
						

							
I Cylinder Head Removal and Installation 
4 Check that two  locating dowels are correctly  positioned in 
block  and are not damaged. 
- Apply  permanently  elastic  sealing compound  Three Bond 
1209 8 to joints  where  cylinder  block joins timing case cover. 
- Place  new cylinder  head gasket  on cylinder block. 
NOTE- 
The  word OBEN or TOP: printed on  the gasket, should 
face  up. The cylinder head 
gasket will fit  correctly in only  one 
orientation. 
- With camshafts  locked in TDC oosition with BMW  soecial 
tools  as described during cylinder  head removal, 
seicylinder 
head in position, guiding  primary chain through  cylinder head 
opening. 
NOTE- 
* The  camshafts must  be locl(ed in the TDC position  at the 
rear  of the cylinder  head with 
BMW special  tool I1 3 240 
before installing  the cylinder  head. 
Make sure the 
cranksha% which  had been rotated approx- 
imately 
30 opposite  the direction of engine rotation, is still 
in that  position  before lowering the  cylinder head into posi- 
tion. 
- Lightly lubricate  new cylinder  head bolts. Loosely  install bolts 
and  their  washers, then  thread them in until  they  are finger 
tight. 
NOTE- 
. Torx-type  cylinder head  bolts should  not be reused.  They 
are  stretch-type bolts  and must always be replaced when- 
ever loosened. 
Check that  all washers for the cylinder  head bolts are in 
place  before installing the bolts.  Some of the washers may 
be 
stalced to  the  cylinder  head. 
CAUTIOI\C 
Cylinder head  bolts for a cast  iron engine block  are different 
length  and require different tightening torque  than bolts for an 
aluminum  cylinder bloclc engines 
(95 rnm versus 110 rnm 
bolts). 
- Install  cylinder  head-to-lower timing chain  cover bolts finger 
tight. 
< Tighten  cylinder  head bolts in correct  sequence to  initial 
torque  value.   
						

							
I Cylinder Head Removal  and Installation I 
< Use BMW  tool 11 2 110 or torque angle  gauge to tighten  cyl- 
inder head bolts in  sequence to stage 
2 and 3. 
Tightening  torques 
Cylinder  head to cast iron 
bloclc 
Staoe 1 
staie 2 
Stage 3 
Cyllnder head to aiumlnum block 
Stage 
1 40  Nm (30 it-lb) 
Stage 2 +90° 
Staoe 3 -80 
- Tighten cylinder head-to-lower timing chain  cover bolts. 
Tightening  torques 
cylinderhead to lower timing chain cover 10 Nm (89 in-lb) 
- Inspect secondary chain  guide rail and tensioner rail for 
grooves caused  by chain  contact.  Replace  any part  that is 
worn. 
NOTE- 
Inspect  timing chain sprocl(ets. Sprockets  that have worn 
or missing  teeth should  be replaced. 
* If any  of the  sprockets  are being replaced due  to wear,  the 
chain  should  also be replaced. 
If the crankshaft  sproclet requir?s replacement, the oil 
pump  drive sprocket  and chain must  be removed  as de- 
scribed under 
119 Lubrication  System. 
The  procedure outlined below  assumes that the camshafts 
and  the 
cranl(shaft are locledin  the TDCposition with special 
4 Mount primary timing chain  sprocltet to primary chain  so that 
arrow on  sprocket faces up. Mount sprocket  to camshaft  so 
that tapped holes  in camshaft  are on left  side  of elongated 
holes in sprocltet 
Install  BMW special tool 
1 I 4 220 into primary timing chain 
tensioner  sleeve. Thread  center spindle in finger tight 
until 
slack is removed  from chain.   
						

							
-- 
Cylinder Head Removal and Installation 
NOTE- 
BMW special tool 11 4 220 is an  adjustable  primary chain 
tensioner  and simulates  the function  of the hydraulic 
tensioner. 
- Check that elongated holes  in primary  sprocket  are now  cen- 
tered  to bolt  holes in camshaft and chain  is free  of slack.  If 
not,  reposition sprocket to chain and  reinstall. 
- lnstall secondary timing chain guide and secondary chain 
tensioner.  Tighten mounting bolts (tensioner remains locked 
down for  now using 
BMW special tool 11 3 292). 
- Install cylinder identification trigger plate to  front of intake 
camshaft with  studs. 
- Install spacer to  front of intake camshaft. 
- Install secondary chain  sprockets and chain as an  assembly 
so  that arrows on  sprockets are pointing up. Center mounting 
holes in  sprockets  to bolt holes in  camshafts. 
4 lnstall thrust washers and diaphragm  spring to intake cam 
sprocket. 
I 2hm thrust  washer I 
- Install shim and torx bolts to exhaust  camshaft. Tighten fin- 
ger tight; do  not torque  down. 
- Tighten intake  sprocket nuts. 
CA UTIOG 
Hold the camshaft stationary  (at hex on  camshaft)  when loos- 
enino or tiahtenino sorocket mounting bolts and studs. 
Tightening  torque 
Intake s~rocket nuts to studs 10 +l Nm (89 +9 in-lb) 
- Turn  crankshaft  approx. 30 in direction  of rotation to bring 
engine  to TDC.  Lock crankshaft in TDC position with  BMW 
special tool 
11 2 300. 
CAUTION- 
The  camshafts  andcranlshaft  must be lockedin  the TDCpo- 
sition using BMW special tools 11 2 300 and 11 3 240. If the 
camshafts and cranl(shaft are not at TDC,  the valves  can 
contact  the pistons.   
						

							
- -. 
Cylinder Head Removal and lnstallation 
NOTE- 
Be Sure  the secondary  timing chain tensioner  is locked  down 
and  the exhaust 
camshaif mounting bolts are  loose  before 
proceeding. 
- Install  VANOS  control unit. See  VANOS control unit, install- 
ing 
(M52 engine)  in 117 Camshaft  Timing Chain. 
CAUTION-- 
Incorrect installation ofthe VANOS control may result in dam- 
age  to the engine  valvefrain. 
- Install exhaust  manifolds using  new gaskets and nuts.  Coat 
manifold studs with copper paste prior  to installing  nuts. 
Install intake camshaft  cover and cylinder 
head cover. 
Check for  correct seating  of half-moon  seals 
(A) in back  of 
cylinder  head cover. 
Use  a small amount  of Three  Bond  1209 
O or equivalent 
sealant  at corners 
(6) of half-moon cutouts. 
Seat gasket  and seal corners  in front  of cylinder  head  at 
VANOS  unit. 
- Installation  of remaining  parts is reverse  of removal,  noting 
the  following: 
Reinstall electrical  harness connectors  for  oil pressure 
switch and coolant temperature sensor  before installing in- 
take  manifold. 
Refill  cooling system as described  in 170  Radiator  and 
Cooling  System. 
Change engine oil  and filter  as described  in 020 Mainte- 
nance. 
If  necessary, adjust  accelerator cable. 
Reconnect battery  last. 
Tightening  Torques 
VANOS  oil  line 
32 Nm  (24 
ft-lb) 
VANOS  solenoid  to control unit 30 Nm  (22 ft-lb) 
Coolant drain  plug to cylinder 
block 25  Nm (18 ft-lb) 
Cylinder  head cover  to cylinder  head 
10 Nrn (89 in-lb) 
(M6 bolts) 
intake manifold  to cylinder  head 15 Nm (I 1 ft-lb) 
Radiator  cooling fan to coolant  pump 
40 Nm (30 ft-lb) - . . 
Radiator drain  screw to radiator 2.5 Nm  (22 in-lbl   
						

							
1 13-22 
Cylinder Head Removal  and Installation 
CYLINDER HEAD REMOVAL AND 
~NSTALLATION (M52 TU AND N154 
ENGINES) 
WARNING - 
Due  to risk  ofpersonal injur)c be sure  the engine  is cold  be- 
fore 
beqinning the  removal  procedure. 
Cylinder head removal and installation is a time consuming 
repair procedure requiring multiple special service  tools. 
Read the entire procedure before beginning the repair. 
This topic includes  the following procedures: 
* Cylinder  head, removing, M52 TU and M54 engines 
Cylinder  head, installing, 
M52 TU and M54 engines 
Cylinder head,  removing, 
M52 TU and M54 engines 
Allow engine to cool before beginning  this procedure. 
- Disconnect negative (-) cable from  battery. 
CAUTION- 
Prior  to disconnecting the  battery, read the battery  discon- 
nection cautions  in 
001 General Cautions  and Warnings. 
4 Remove  left and right interior ventilation ducts  (left side 
shown): 
Release ventilation filter  cover latch 
(A) and remove  cover. 
Release plastic locking  tab 
(6) or release locking  tabs on 
top  of duct (later models). 
= Turn  duct counterclocltwise  to unlock  from bullthead  and 
remove  (arrow). 
Disconnect electrical harness  from hood switch (C). 
Release spring  lock fastener 
(D). 
- Slide filter housing  away from inner  fender  to remove. 
Removal  of right side ventilation 
dud 
Remove  rear bulkhead  panel: 
Lift  off rubber sealing 
gasket (arrow) 
- Remove 3 mounting clips (A). 
Remove 4 retaining  screws (6). 
Lift off panel. 
: is similar   
						

							
- -- 
Cylinder Head Removal  and Installation 1 -- 
< Remove  complete  air filter housing  assembly  with mass  air 
flow  sensor: 
Loosen 
intalte duct  hose  clamp  (A) at throttle  assembly. 
Loosen  clamp and remove  idle control line from intake duct 
(B) and  disconnect  idle  speed control  valve electrical har- 
ness  connector. 
Disconnect electrical harness connector 
(C) from mass air 
flow sensor. 
Remove air filter  housing mounting screw 
(D). 
Disconnect vent  tube (E). 
. Loosen air intalte duct clamp (F). 
Carefully lifl air filter housing, mass  air flow sensor, and in- 
take duct  hose out of engine  bay. 
4 Disconnect  positive  battery cable and  remove  intake rnani- 
fold cover: 
Remove protective cover from positive  (+)jumper post. 
Loosen  and remove battery  lead mounting nut (A). 
Remove  lead and push  down through intake manifold. 
* Remove  trim covers  (arrows)  from fuel injector  cover. 
Remove cover  hold down fasteners and  lifl off  cover. 
4 Worlting above engine, disconnect the following: 
Vent  line from  cylinder  head cover.  To remove, pinch  clips 
(arrows). 
Electrical harness connector from  VANOS solenoid  valve 
(A). 
- Remove oxygen sensors and exhaust manifolds.  See 180 
Exhaust System. 
CAUTION- 
Remove oxygen sensors before removing exhaust mani- 
fold  to prevent  damage. 
Label  oxygen  sensor harness  connectors  so that  they 
can  be reassembled correctly  Do not  interchange  con- 
nectors. 
NOTE- 
Front  exhaust  manifold must  be removed before rear 
manifold.   
						

							
. .- - 
Cylinder Head Removal and Installation 
- Working at side  of intake  manifold near left strut  tower, dis- 
connect intake manifold resonance  valve electrical harness 
connector. 
4 Disconnect fuel injector electrical harness connectors  from 
injectors. 
- Use small screwdriver to pry  out wire lock clip on fuel injec- 
tor 
1 connector. 
Repeat  for remaining injectors. 
Release harness conduit  fasteners from injector  rail. 
- Disconnect intake air temperature  sensor electrical har- 
ness  connection (between  intake runners  for cylinders 
3 
and 4). 
Lift  off connector assembly  and lay aside. 
4 Where  applicable,  remove schraeder  valve cap (arrow)  from 
fuel 
ra~l. Using a tire chuck,  blow fuel back through  feed line 
using a brief burst  of compressed air (maximum  of 
3 bar or 
43.5 psi). 
WARNING- 
Fuel  is underpressure  (approx. 3 - 5 bar or 45 - 75psi) and 
may  be expelled.  Do not  smoke  or 
work near heaters  or 
other  fire  hazards.  Keep a fire  extinguisher  handy Before 
d~sconnecting fuel hoses,  wrap a cloth around fuel  hoses 
to  absorb  any leaking  fuel. Catch  and 
dfspose of escaped 
fuel.  Plug  all open fuel  lines. 
Always unscrew the  fuel tank  cap to release pressure 
I in the tank before working on  the tank or lines. 
Disconnect manifold  vacuum line (arrow) 
Raise car  and support in a safe manner, 
CAUTION- 
Make  sure the car is stable  and well supported  at all times. 
Use  a professional  automotive lift 
orjack stands designed  for 
the  purpose.  A 
floorjack is not  adequate  support. 
Remove  protective engine  splash guard from  below engine.   
						

							
11 3-25 
Cylinder Head Removal and Installation 
4 Working  beneath car (on left side  under driver seat),  remove 
fuel  filter  cover  and clamp 
off fuel hose(s). 
NOTE- 
M54 engines  use a single fuel line to  the non-return fuel rail. 
Disconnect  fuel  lines by pressing  in on  spring  lock (arrows). 
CAUTION-- 
Fuel  may be expelled  underpressure. Do not smoke or worlc 
near heaters or other fire hazards.  Keep a fire extinguisher 
handy  Before disconnecting fuel hoses, wrap  a cloth  around 
fuel hoses  to absorb any  leaking fuel. Plug  all open  fuel lines. 
NOJE- 
BMW uses  various styles of line connections;  a one-time 
band clamp; a 
self-locl(ing connector (that  use BMWspecial 
tool 16 1 050 to release);  and a quick release connector 
(above). 
4 M52 TU engine:  Pull throttle  cable out of rubber  retainer (A) 
and  unhook  ball  end  of cable (6) from throttle actuator. 
4 Remove fasteners  retaining wiring harness  at throttle  body 
and  support  bracket  (arrows).   
						

							
. - -- 
j Cylinder Head Removal and Installation 
4 Working at throttle  housing, unscrew  and disconnect electri- 
cal harness  plug 
(arrow). 
4 Disconnect electrical harness connector  at fuel tank venting 
valve 
(A) and  vent  hose  at quick disconnect fitting (arrow). 
- Working  under intake manifold, disconnect  the following: 
Engine  oil dipstick tube support. 
Oil  separator  return line from dipstick tube. 
Knock sensor  harness connector from  support. 
4 Working  underneath  car, remove intake manifold support 
mounting  nut 
(arrow), located adjacent  to left engine mount.