Honda Bmw 5 Service Manual
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Cylinder Head Removal and Installation / 4 Remove top engine cover by releasing quick release fasten- ers (arrows) by pressing down. NOTE- Earlier models may have an engine cover with pry off caps and fasteners In place of quick release fasteners. 4 Remove left and right interior ventilation ducts (left side shown): - Release locking tabs (A) or locking strap (early models, not shown). Release spring lock (B). * Rotate duct inward (arrow) to remove. Disconnect electrical harness from hood light switch (C). Release locking clip and remove ventilation housing cover (D). Lift out housing from inner fender. - Removal of right side ventilation housing is similar. 4 Air filter housing assembly, removing: Disconnect electrical harness connectors from mass air flow sensor (A) and temperature sensor (B). Loosen hose clamp (C). Remove filter housing mounting fastener (arrow) and re- move filter housing with mass air flow sensor.
Cylinder Head Removal and Installation Pry out ignition coil cover trim caps, covers from lefl and right sides. remove fasteners and < Disconnect throttle cables from throttle shafl (A) and remove cables from support bracket (B). < Disconnect cable from jump start post (arrow) on left cylinder head cover.
- .- .. Cylinder Head Removal and Installation I - < Disconnect the following electrical harness connectors: Knock sensors (A). Thermostat (6). Throttle position sensor and idle valve (C). Camshaft position sensor (D). Ignition coils (E). < Remove mounting nuts (arrows) from wiring harness ducts. 4 Release fuel injector connectors by releasing spring clip (arrow) on each injector. Lift up and remove electrical ducts and set to one side
1 13-60 Cylinder Head Removal and Installation Label and disconnect fuel lines from fuel rail by pressing lock- ing sleeves (arrows) in to release lines. NOTE- BMW uses three styles of fuel line connections; a single use clamp; a locking fitting that uses special tool 16 1 050 to re- lease; and a quick release sleeve (arrow) that disconnects the line when depressed. CAUTION- Fuel may be expelled under pressure. Do not smoke or work near heaters or other fire hazards. Keep a fire exfin- guisher handy Before disconnecting fuel hoses, wrap a cloth around fuel hoses to absorb leaking fuel. Plug all I ooen fuel lines. I Always unscrew fuel tank cap to release pressure in tank before removinq fuel lines. Cap fuel lines and fuel rail inlets. Disconnect vacuum lines (A, B and C) from rear of intake manifold. Working at rear of intake manifold, disconnect crankcase ventilation valve from pipe by prying up on lock (A) and slid- ing tube forward (B).
11 3-61 Cylinder Head Removal and installation I Remove intake manifold fasteners (A). Carefully lift intake manifold off engine while checking that all hoses and harnesses have been disconnected. Left cylinder head, removing, M62 engine - Remove intake manifold as described earlier - Remove left side exhaust manifold. See 180 Exhaust Sys- tem. - Drain engine coolant, then remove viscous clutch cooling fan. See 170 Radiator and Cooling System. WARNING - Use extreme caution when draining and disposfng of eng~ne coolant. Coolant is poisonous and lethal to humans andpets. Pets are attracted to coolant because of its sweet smell and taste. Seek med~cal attention immediately if coolant is ingest- ed. 4 Remove coolant manifold mounting fasteners and carefully remove manifold. NOTE- Engine shown removed from engine bay 4 Remove ignition coil fasteners and coils (noting location of ground strap). - Remove spark plugs.
. .- -- [Cylinder ~ead Removal and Installation 4 Remove cylinder head cover fasteners (arrows) and remove covers from left and right cylinder heads. 4 Remove oil distribution tubes from camshaft bearing caps from left and right cylinder heads. 4 Using crankshaft center bolt, turn crankshaft clockwise until number one cylinder (passenger side front cylinder) is in TDC overlap position (arrow). NO JE - Number one cylinder is at valve overlap when both the intake and exhaust valves are starting to open (camshaft lobes fac- ing down). 4 Working at right cylinder head, loosen three accessible cam- shaft sprocltet fasteners (arrows) on both intake and exhaust camshafts approximately I2 turn. To prevent valve to piston contact when loosening camshaft sprocket fasteners, counterhold camshaft with 27 mm open- end wrench. If necessary, grind outerside of wrench jaws to prevent damaging cylinder head.
.- -- Cylinder Head Removal and Installation I 4 Rotate crankshaft vibration damper to TDC position. Right head camshaft lobes for number one cylinder should be in position shown (arrows). Working at right cylinder head (passengers side) loosen re- maining sprocltet fasteners (arrows) on both intake and ex- haust camshafts approximately /? turn. 4 Loosen and remove primary timing chain tensioner (arrow) from upper timing chain cover on right head.
1 13-64 Cylinder Head Removal and Installation < Remove upper timing chain cover fasteners (A) and cover from left cylinder head. 4 Remove fasteners from intake camshaft sprocket (arrows) on left cylinder head. - Remove primary timing chain sprocket and suspend timing chain using mechanics wire to prevent chain from dropping into lower housing. Turn crankshaft counterclockwise until 45 mark on crank- shaft is aligned with boss on front timing chain cover (arrow).
1 13-65 Cylinder Head Removal and Installation / Loosen chain rail set screw (arrow) 3 full move). NOTE- Allen screw secures crankcase vent tube 4 Loosen and turns (do not re- in cylinder head. remove chain guide rail fasteners (arrow). Slide oil separator (A) out of cranltcase vent connecting bracket (arrows). CAUTIOI\C When removing the cylinder head carefully press oil separa- tor outwards. Loosen cylinder head bolts in sequence 1-10 as shown (ar- rows) and discard used head bolts. Lift cylinder head off engine block while pressing out on oil separator. CAUTIOI\C Be careful not to damage oil separator while removing cylin- der head.
. .- -- I Cylinder Head Removal and Installation - Evaluate cylinder head as described in 116 Cylinder head and valvetrain. Left cylinder head, installing, M62 engine - Clean cylinder head and block sealing surfaces of gasket debris, making sure no debris drops into coolant or oil pas- sages. - Clean cylinder head bolt holes and check condition of threads. < Check cylinder head locator sleeves (arrows) for damage. If the cylinder head has been machined, a special 0.3 mm thicker gasket should be installed. The thicker gasket is avail- able through an authorized BMW dealer and should be marked accordingly. - Place new cylinder head gasket over locating sleeve on block. The word OBEN or TOP (arrow) printed on the gasket, must face up. Set lefl side cylinder head in position on cylinder block while pressing oil separator outward. CAUJION- Male sure the crankshaft, which had been rotated approxi- mately 45 opposite the direction of engine rotation from TDC, is still in thatposition before installing the cylinder head. All pistons must be out of TDCposition to prevent valvelpis- ton contact. - Install new cylinder head bolts and washers finger tight. Be sure not to remove coating from new cylinder head bolts. 4 Tighten cylinder head bolts in correct sequence (1-10) to stage 1 torque values.