Honda Bmw 5 Service Manual
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1 13-67 Cylinder Head Removal and lnstaKI -- < Using a torque angle gauge, tighten cylinder head bolts to specified torque angle in stages 2 and 3. Tightening torques Stage I 30 Nrn (22 ft-lb) Stage II +80° Stage Ill +80° 4 If possible, confirm oil return pipe at bottom of separator is correctly seated (arrow). NOTE- Photo shows lower timing case cover removed. < Remove old O-ring and install new O-ring (arrow) in angle section. - Press oil separator into angle section and install guide rail re- taining screws. 4 Tighten allen screw (arrow) just until it makes contact with crankcase vent tube angle section without play. NOTE- Allen screw secures crankcase vent tube in place. Do not torque down.
11 3-68 Cylinder Head Removal and Installation < Using BMW special tool 11 3 430, or a 27 mm open-ended wrench, rotate camshafts to cylinder 1 TDC position (until markings point upwards). I I < Install camshaft locltina tool set (BMW soecial tool set 11 2 440) on right cylinder head (cylinders 1-4). Fit on cylinde~ head without gaps. Install camshaft locking tool set (BMW special tool set 11 2 440) on left cylinder head (cylinder head 5-8). Fit on cylinder head without gaps. 4 Using crankshaft center bolt, rotate engine clockwise from the 45 mark to TDC position (OIT aligns with casting mark on cylinder block).
11 3-69 Cylinder Head Removal and Installation 4 Lock crankshaft in TDC position with BMW special tool 11 3 200 (arrow). NOTE- Boss for special tool 11 3 200 located at rear of engine oil pan. 4 Working at left cylinder head (drivers side) fit primary sprock- et and chain to camshaft flange, centering threaded bores. Insert bolts (arrows) and hand tighten. ?-I I 4 Install BMW special tool 11 3 390 into right timing case cover. NOTE- BMW special tool 00 9 250 is a flexible shaft torque wrench. I - Tighten sprocket retaining bolts in the following order: All bolts on left cylinder head exhaust camshaft 3 accessible bolts on right cylinder head exhaust camshaft All bolts on left cylinder head intake camshaft 3 accessible bolts on right cylinder head intake camshaft r....7n Tightening torques Sprocltet bolts to camshait flange 15 Nm (11 ft-lb) - Remove camshaft and crankshaft locking tools from engine. - Using crankshaft center bolt, turn engine clockwise to access remaining sprocket retaining bolts of right cylinder head cam- shafts. Tighten remaining bolts. Tightening torques Sprocket bolts to camshaft flange 15 Nm (11 ft-lb)
11 3-70 Cylinder Head Removal and Installation - Remove adjustable timing chain tensioner tool from timing case cover and install primary timing chain tensioner with new sealing washer. Tightening torque Chain tensioner cylinder to timing cover 65 Nm (48 ft-lb) 4 Install oil supply lines and mounting nuts (arrows) to both heads. Tightening torque Oil supply line nuts 10 Nm (7.5 ft-lb) - Remove old gasket from lefl timing cover, and clean gasket surface. 4 Apply Three Bond 1209 8 sealant to joint between cylinder head and timing cover (arrows). Using a new gasket, install lefl timing cover with lower inner fastener inserted in cover (arrow). Position cover in place and tighten cover fasteners finger tight. NOTE- It is not possible to install lower inner fastener after cover is in place.
. . . . I - Cylinder Head Removal - and instard -- 4 Remove left cylinder head cover gasket and install spacing tool (BMW 11 1 412) in place of gasket. - lnstall lefl cylinder head cover fasteners and tighten uniformly in I2 turn steps. Tightening torque Cylinder head cover nuts 10 Nrn (7.5 it-lb) - Tighten left upper timing cover retaining bolts in two passes. Tightening torque Timing chain cover to head 10 Nrn (7.5 ft-lb) - Remove lefl cylinder head cover and BMW special tool 11 4 412. 4 Reinstall cylinder head covers to left and right cylinder heads using new gaskets. Check for correct seating of half-moon seals (A) in back of cylinder head cover. Use a small amount of Three Bond 1209 03 or equivalent sealer at corners (6) of half-moon cutouts. - Install left cylinder head cover fasteners and tighten uniformly in I? turn steps. - Install exhaust manifolds using new gaskets and fasteners. See 180 Exhaust System.
/Cylinder Head Removal and Installation - Remainder of installation is reverse of removal, noting the fol- lowing: Use new gaskets when mounting intake manifold. Tighten nuts finger tight first, then torque to specification in stages working diagonally from center out. Be sure to reinstall ignition coil ground straps at cylinders no. 3 and no. 7. See 120 Ignition System. Reinstall cooling fan and shroud. See 170 Radiator and Cooling System. Refill and bleed cooling system as described in 170 Radi- ator and Cooling System. Change engine oil and filter as described in 020 Mainte- nance. CA UTIOG To prevent damaging engine electricalsystems, be sure to in- stall all ground wires previously removed. Tightening torques Camshaft sprocket to camshaft 15 Nm (11 H-lb) Coolant manifold to cylinder head 10 Nm (7.5 H-lb) Cylinder head cover nuts 10 Nm (7.5 ft-lb) Exhaust manifold to head 22 Nm (17 ft-lb) Engine mounts to subirame 42 Nm (30 ft-lb) Spark plugs to cylinder head 22 Nm (17 ft-lb) Right cylinder head, removing, M62 engine - Remove left side exhaust manifold. See 180 Exhaust Sys- tem. - Remove intake manifold. See Intake manifold, removal and installation, M62 engine. - Drain engine coolant. See 170 Radiator and Cooling Sys- tem. WARNING- Use extreme caution when draining and disposing of engine coolant. Coolanl is poisonous andlellial lo liumans andpels. Pets are altracled to coolant because of 11s sfieet smell and fasle. Seelc medcal anenfion immed~alely if coolant is ingesl- . .- < Remove engine coolant manlold mo~nlng fasreners and carei~lly remove manifo d. . I NOTE Engine 8s slioivn removed lor clarify
11 3-73 Cylinder Head Removal and Installation / 1 - Remove viscous clutch cooling fan. See 170 Radiator and i Cooling System. i i I 4 Remove ignition coil fasteners and coils (noting location of ~ ground strap). 1 Remove sparlc plugs. i Remove oil distribution tube fasteners and remove tubes from both cylinder heads. 4 Using crankshaft center bolt, turn crankshaft cloclcwise until number one cylinder (front cylinder right side) is in TDC (ar- rows).
11 3-74 Cylinder Head Removal and Installation 4 Work at left side cylinder head loosen three accessible cam- shaft sprocket fasteners (arrows) on both intake and exhaust camshafts approximately I2 turn. Toprevent valve topiston contact, counterholdcamshaft with 27 mm open-end wrench whenever loosening or tightening camshaft sprocket fasteners. If necessarq! grind outer side of wrench jaws to prevent damaging cylinder head. 4 Rotate crankshaft one complete rotation to TDC overlap. Right (passengers side of engine) side camshaft lobes for number one cylinder should be in overlap position as shown (arrows). 4 Working at left cylinder head, loosen remaining sprocket fas- teners (arrows) on both intake and exhaust camshafts ap- proximately I2 turn.
1 13-75 Cylinder Head Removal and Installation I 4 Loosen and remove primary timing chain tensioner (arrow) from right cylinder head. Remove camshaft position sensor (arrow) chain cover on right cylinder head. Remove dip stick tube support fastener. from upper Remove upper timing chain cover fasteners (A) and cover from right cylinder head. timing remove
1 13-76 Cylinder Head Removal and Installation Remove fasteners from intake camshaft sprocket (arrows) on right 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) 4 Loosen cylinder head bolts in sequence 1-10 as shown (ar- rows) and discard used head bolts. - Evaluate cylinder head. See 116 Cylinder head and val- vetrain.