How to remove Cylinder Head on 2005 BMW 325 ?

There are 2 cylinder heads :---

For cylinder head 1 click this link below:---

http://bmwrepairhelp.blogspot.com/2011/09/how-to-remove-cylinder-head-on-2005-bmw.html

For cylinder head 2 read as follows :---

M60/M62 Engines

1. Disconnect negative battery cable.
2. Remove both exhaust manifolds from each side of the engine. Remove the heat shields from the front axle carrier.
3. Drain the engine coolant, and remove the coolant expansion tank.
4. Remove the upper timing case cover.
5. Remove the oil pipes on the cylinder head.
6. Remove the intake manifold.
7. Remove the cylinder head cover.
8. Remove the engine vent pipe together with the O-ring. Disconnect all the coolant hoses on the coolant collector. Remove the coolant collector mounting bolts, and remove the coolant collector.
9. Remove all eight spark plugs.
10. Remove the camshaft sprockets, and the timing chain tensioner.
11. Remove the bolts retaining the guide rail on the cylinder head's left hand side.
12. Remove the cyclone oil trap.
13. Remove the cylinder head bolts from the outside to inside. Lift off the cylinder head.
    
    NOTE

    The cylinder head bolts must be replaced.
    
    

To install:

1. Thoroughly clean all mounting surfaces and check the head for warpage. Take care not to drop any pieces of gasket or dirt into the oil or coolant passages. Check the condition of the head locating dowel sleeves and clean out the bolt threads with a tap.
2. Mount the cylinder head and new bolts. Torque the bolts in the proper sequence in three steps:
   
   
   Step 1-Torque each bolt to 24 ft. lbs. (32 Nm)

   Step 2-Wait 10 to 20 minutes, then turn each bolt an additional 80°

   Step 3-Wait 10 to 20 minutes, then turn each bolt an additional 80°
   
   
3. Install the cyclone oil trap.
4. Install the bolts retaining the guide rail on the cylinder head's left hand side.
5. Install the camshaft sprockets and the timing chain tensioner. Torque the sprocket mounting bolts to 11 ft. lbs. (15 Nm).
6. The remaining components are installed in the reverse order from which they were removed.
7. Connect negative battery cable.

M62 4.4L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   NOTE

   The cylinder head bolts must be replaced.
   
   
   
   
   Negative battery cable

   Both exhaust manifolds from each side of the engine, then remove the heat shields from the front axle carrier

   Coolant expansion tank

   Upper timing case cover

   Oil pipes from the cylinder head

   Intake manifold

   Cylinder head cover

   Engine vent pipe together with the O-ring, disconnect the coolant hoses on the coolant collector, remove the coolant collector mounting bolts, and then remove the coolant collector

   Spark plugs

   Camshaft sprockets, and the timing chain tensioner

   Bolts retaining the guide rail on the cylinder head's left-hand side

   Cylinder head bolts in the reverse order of the tightening sequence

   Cylinder head
   
   

To install:

Fig. Cylinder head torque sequence-M62 4.4L engine

1. Thoroughly clean all mounting surfaces and check the head for warpage. Take care not to drop any pieces of gasket or debris into the oil or coolant passages. Check the condition of the head locating dowel sleeves and clean out the bolt threads with a tap.
2. Mount the cylinder head on the block and use new bolts. Do not remove the coating on the head bolts. Apply oil to the threads and torque following the tightening sequence in 3 steps as follows:
   
   
   Step 1: 22 ft. lbs. (30 Nm)

   Step 2: 80 degrees

   Step 3: 80 degrees
   
   
3. The balance of installation is the reverse of the removal procedure.
4. Fill the cooling system.
5. Start the engine and check for leaks.
   
   NOTE

   It may be necessary to bleed the cooling system a second time after the engine has been started.
   
   

M62 Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   NOTE

   The cylinder head bolts must be replaced.
   
   
   
   
   Negative battery cable

   Both exhaust manifolds from each side of the engine, then remove the heat shields from the front axle carrier

   Coolant expansion tank

   Upper timing case cover

   Oil pipes from the cylinder head

   Intake manifold

   Cylinder head cover

   Engine vent pipe together with the O-ring, disconnect the coolant hoses on the coolant collector, remove the coolant collector mounting bolts, and then remove the coolant collector

   Spark plugs

   Camshaft sprockets, and the timing chain tensioner

   Bolts retaining the guide rail on the cylinder head's left-hand side

   Cylinder head bolts in the reverse order of the tightening sequence

   Cylinder head
   
   

To install:

Fig. Cylinder head torque sequence-M62 engines

1. Thoroughly clean all mounting surfaces and check the head for warpage. Take care not to drop any pieces of gasket or debris into the oil or coolant passages. Check the condition of the head locating dowel sleeves and clean out the bolt threads with a tap.
2. Mount the cylinder head on the block and use new bolts. Do not remove the coating on the head bolts. Apply oil to the threads and torque following the tightening sequence in 3 steps as follows:
   
   
   
   
   1. Step 1: 22 ft. lbs. (30 Nm).
   2. Step 2: 80 degrees.
   3. Step 3: 80 degrees.

   
   
3. The balance of installation is the reverse of the removal procedure.
4. Fill the cooling system.
5. Start the engine and check for leaks.
   
   NOTE

   It may be necessary to bleed the cooling system a second time after the engine has been started.
   
   

M73 5.4L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Exhaust pipe connections at the manifold and at the transmission pipe clamp

   Splash shield from under the engine

   Engine oil

   Fan shroud and engine cooling fan

   Fresh air inlet hose and air cleaner housing

   Idle speed control valve. To do so, loosen the hose clamps and remove the hoses. Detach the electrical connector. Remove the mounting nut, then pull the idle speed control out of the air intake hose.

   Retainers for the air flow sensor, then pull the unit off the mounts, and disconnect the vacuum hose from the PCV system

   Electrical connector from the coolant expansion tank. Remove the nuts on both sides. Loosen the clamps, then disconnect all hoses and remove the tank.

   Heater hoses at both the control valve and at the heater core and remove the valve

   Throttle and cruise control cables at the throttle lever. Unbolt the cable housing retainer and remove the housing and cables.

   Plugs near the thermostat housing. Loosen the hose clamps and remove the coolant hoses.

   Connector for the O ₂ S sensor. Disconnect the surrounding electrical connectors.

   Fuel supply and return lines

   Fuel pipe running along the cylinder head, near the manifold, then remove the electrical connector at the throttle body

   Bracket covers, then remove the attaching bolts, wiring harness and carrier for the fuel injectors

   Ignition coil high tension lead, the high tension wires at the spark plugs, then, remove the mounting nuts and the carrier for the high tension wires from the head

   Camshaft cover
   
   
5. Turn the engine until the timing marks are at TDC with the cylinder number 6 valves at overlap. Both valves should be slightly open.
6. Remove or disconnect the following:
   
   NOTE

   The cylinder head bolts must be replaced.
   
   
   
   
   Upper timing case cover

   Timing chain tensioner piston

   Upper timing chain sprocket bolts and pull the sprocket off, and while holding it upward, support it securely so the relationship between the chain and sprockets both top and bottom will not be lost

   Upper radiator hose at the thermostat housing, then remove the bolts and remove the support for the intake manifold

   Cylinder head bolts in reverse of the tightening sequence

   Cylinder head
   
   

To install:

Fig. Cylinder head torque sequence-M73 5.4L engines

1. Thoroughly clean all mounting surfaces and check the head for warpage. Check the condition of the head locating dowel sleeves and clean out the bolt threads with a tap.
2. Check the cylinder head and block deck surface to be sure they are true and install a new head gasket.
   
   NOTE

   Use a thicker head gasket if the head has been machined.
   
   
3. Apply sealant to the joints between the engine block and the upper and lower timing covers.
4. Mount the cylinder head on the block and use new bolts. Do not remove the coating on the head bolts, apply oil to the threads and torque following the tightening sequence in 3 steps as follows:
   
   
   Step 1: 22 ft. lbs. (30 Nm)

   Step 2: 60 degrees

   Step 3: 60 degrees
   
   
5. Reinstall the timing sprocket to the camshaft. Be sure the camshaft is in proper time and use new lockplates. The camshaft for cylinder number 1 is at TDC firing position when the recess of the camshaft flange is flush with the bolt holding the oil baffle.
6. The balance of installation is the reverse of the removal procedure.
7. Fill the cooling system.
8. Start the engine and check for leaks.
   
   NOTE

   It may be necessary to bleed the cooling system a second time after the engine has been started.
   
   

N52 Engines

CAUTION

Aluminum-magnesium material. No steel fasteners may be used due to the threat of electrochemical corrosion. A magnesium crankcase requires aluminum fasteners exclusively. Aluminum fasteners must be replaced each time they are removed. The end faces of aluminum fasteners are painted blue for purposes of identification. Torque specifications and torque angles must be observed for risk of damage.

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system and engine oil.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   CAUTION

   If the timing chain is stored in the gearcase, the crankshaft must not be rotated. Only during assembly can the timing chain be lifted out.
   
   
   
   CAUTION

   After removing, secure magnet wheel in a plastic bag.. Magnet wheel must be protected against metal chips.
   
   
   
   
   Exhaust system

   Both exhaust manifolds

   Intake manifold

   Coolant hoses from cylinder head

   Cylinder head cover

   Inlet and exhaust adjustment unit
   
   
   
   
   Timing chain module and fasteners

   Eccentric shaft sensor and fasteners towards front
   
   
   
   
   Magnet wheel and fastener towards front
   
   
5. Pretension eccentric shaft upwards. Remove mini stop screw between first and second cylinders
6. Use special tool Torx Socket T60 (No. 115190) to remove M10 fasteners. Use special tool Torx Socket T50 (No. 114420) to remove M9 fasteners.
   
   CAUTION

   Do not set cylinder head down on sealing face, risk of damage to engine valves.
   
   
7. Remove cylinder head. Install seal plugs into bores.
   
   CAUTION

   Do not use any metal cutting tools for cleaning.
   
   
8. Thoroughly clean all mounting surfaces of gasket remnants and check the head for warpage. Take care not to drop any pieces of gasket or debris into the oil or coolant passages. Check the condition of the head locating dowel.
   
   NOTE

   The cylinder head bolts must be replaced.
   
   
   
   
   

   

   Fig. Cylinder head bolt sequence on N52 engines

To install:

Install bolts 1-10 with special tool No. 115190. Install bolts 11-14 with special tool No. 114420.

Torque following the tightening sequence as follows:

1. Step 1:Bolts 1-14: 22 ft. lbs. (30 Nm).
2. Step 2: Bolts 1-14: 90 degrees.
3. Step 3: Bolts 1-10: 90 degrees.
4. Step 4: Bolts 1-14: 42 degrees

1. The balance of installation is the reverse of the removal procedure.
2. Fill the cooling system.
3. Start the engine and check for leaks.

N62 Engines
Left Side

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Left exhaust manifold

   Ignition coils

   Eccentric shaft servo motor

   Cylinder head cover

   Intake manifold

   Timing case cover

   Engine wiring harness and secure aside

   Spark plugs

   Vent hose from cylinder head

   Hose and check valve. Do not remove the guide tube for the dipstick.
   
   
5. Rotate the eccentric shaft at the dihedral head to reduce tension on the torsion spring. Pull on the torsion spring with a strap and rotate it out from the roller.
6. Rotate the dihedral head eccentric shaft back to the minimum stroke position.
7. Remove or disconnect the following:
   
   
   Mounting screw and spring mount from locating pin

   Eccentric shaft sensor

   Guide rail from cylinder head

   Screws between cylinder head and timing case cover

   Slacken cylinder head bolts in sequence one turn from 10 to 1

   Rotate the eccentric shaft and remove bolt 7

   Rotate the eccentric shaft back and remove the remaining cylinder head bolts

   Cylinder head
   
   

To install:

1. Thoroughly clean all mounting surfaces and check the head for warpage. Take care not to drop any pieces of gasket or debris into the oil or coolant passages. Check the condition of the head locating dowel sleeves and clean out the bolt threads with a tap.
2. Coat the joint between the engine block and timing case cover with Drei Bond 1209.
3. Mount the cylinder head on the block and use new bolts. Do not remove the coating on the head bolts. Apply oil to the threads and washer contact area. Rotate the eccentric shaft to insert bolt 7. Torque following the tightening sequence as follows:
   1. Step 1: 22 ft. lbs. (30 Nm).
   2. Step 2: 90 degrees.
   3. Step 3: 90 degrees.

   
   
4. The balance of installation is the reverse of the removal procedure.
5. Fill the cooling system.
6. Start the engine and check for leaks.
   
   
   

   

   Fig. Rotate the eccentric shaft (1), pull on the torsion spring and rotate out from roller (3)

   
   
   
   

   

   Fig. Cylinder head bolt sequence on N62 engines

Right Side

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Right exhaust manifold

   Ignition coils

   Eccentric shaft servo motor

   Cylinder head cover

   Intake manifold

   Timing case cover

   Engine wiring harness and secure aside

   Spark plugs

   Vent hose from cylinder head

   Hose and check valve
   
   
5. Slacken chain tensioning piston by one turn. Rotate the eccentric shaft at the dihedral head to reduce tension on the torsion spring. Pull on the torsion spring with a strap and rotate it out from the roller.
6. Rotate the dihedral head eccentric shaft back to the minimum stroke position.
7. Remove or disconnect the following:
   
   
   Mounting screw and spring mount from locating pin

   Eccentric shaft sensor

   Guide rail from cylinder head

   Screws between cylinder head and timing case cover

   Slacken cylinder head bolts in sequence one turn from 10 to 1

   Rotate the eccentric shaft and remove bolt 7

   Rotate the eccentric shaft back and remove the remaining cylinder head bolts

   Cylinder head

   Chain tensioning piston
   
   

To install:

1. Place piston on a level surface and compress slowly. Repeat twice.
2. Thoroughly clean all mounting surfaces and check the head for warpage. Take care not to drop any pieces of gasket or debris into the oil or coolant passages. Check the condition of the head locating dowel sleeves and clean out the bolt threads with a tap.
3. Coat the joint between the engine block and timing case cover with Drei Bond 1209.
4. Replace sealing ring on piston. Install piston and tighten unit there is no play.
5. Mount the cylinder head on the block and use new bolts. Do not remove the coating on the head bolts. Apply oil to the threads and washer contact area. Rotate the eccentric shaft to insert bolt 7. Torque following the tightening sequence as follows:
   
   
   
   
   1. Step 1: 22 ft. lbs. (30 Nm).
   2. Step 2: 90 degrees.
   3. Step 3: 90 degrees.

   
   
6. The balance of installation is the reverse of the removal procedure.
7. Fill the cooling system.
8. Start the engine and check for leaks.

S14 Engine

1. Disconnect the negative battery cable. Remove the splash guard from under the engine. Put drain pans underneath and remove the drain plugs from both the radiator and block to drain all coolant.
2. Loosen the hose clamps for the air intake hose located next to the radiator and then remove the hose. Disconnect the electrical connectors for the airflow sensor. Then, remove the attaching nuts and remove the air cleaner/ airflow sensor unit.
3. Disconnect the accelerator and cruise control cables. Unbolt the cable mounting bracket and move the cables and bracket aside.
4. Remove the attaching nut, pull off the clamp, and then detach the vacuum hose from the brake booster.
5. Loosen the hose clamp and remove the air intake hose from the intake manifold. Remove the nut from the manifold brace.
6. Loosen the clamp and disconnect the other end of the booster vacuum hose at the manifold. Remove the nut from the intake manifold brace.
7. Loosen the hose clamp and disconnect the air intake hose at the manifold. Then, remove the nuts attaching the manifold assembly to the outer ends of the intake throttle necks and remove the assembly.
8. Put a drain pan underneath and loosen the hose clamps and disconnect the coolant expansion tank hoses. Disconnect the engine ground strap.
9. Disconnect the ignition coil high tension lead. Label and then disconnect the plugs on the front of the block. Remove the nut fastening the lead farther forward of the plugs and move the lead aside so it will not interfere with cylinder head removal.
10. Find the vacuum hose leading to the fuel pressure regulator. Pull it off. Label and then disconnect the 2 plugs. Unscrew the mounting screw for the electrical lead connecting with the top of the block and remove the lead and its carrier.
11. There is a vacuum hose connecting with one of the throttle necks. Disconnect it and pull it out of the intake manifold bracket. Pull off the electrical connector. Pull out the rubber retainer, and then pull the idle speed control out and put it aside. The engine wiring harness is located nearby. Take it out of its carriers.
12. All the fuel injectors are plugged into a common plate. Carefully and evenly pull the plate off the injectors, pull it out past the pressure regulator, and lay it aside.
13. Loosen the clamp and then disconnect the PCV hose. Label and then disconnect the fuel lines connecting with the injector circuit. Put a drain pan underneath and then disconnect the heater hose from the cylinder head.
14. Loosen the clamp near the throttle necks and then pull the engine wiring harness out and put it aside. Put a drain pan underneath and then disconnect the heater hose that connects to the block.
15. Remove the bolts from the flanges connecting the exhaust pipes to the exhaust manifold. Provide new gaskets and self-locking nuts. Disconnect the oxygen sensor plug.
16. Put a drain pan underneath and then disconnect the radiator hoses from the pipe at the front of the block.
17. Pull off the spark plug connectors. Remove the nuts from the camshaft cover, located just to one side of the row of spark plugs. Remove the ignition lead tube. Remove the remaining nuts and remove the camshaft cover. Provide new gaskets.
18. It is not necessary to remove the timing chain completely, but it is necessary to remove the camshaft cover, front covers for the camshaft drive sprockets, the upper guide rail for the timing chain and then turn the engine to the Top Dead Center (TDC) firing position for cylinder number 1.
19. Remove the timing chain tensioner. Note the relationship between the chain and both the crankshaft and camshaft sprockets, and then remove both camshaft drive sprockets. Leave the chain in a position that will not interfere with removal of the head and which will minimize disturbing its routing through the areas on the front of the block.
20. Remove the camshafts. Use care to remove the camshaft followers one at a time, keeping them in exact order for installation in the same positions.

NOTE

The camshaft caps and followers must be kept in order to ensure proper reinstallation.

1. Remove the bolts, some are accessible from below, that retain the timing case to the head at the front, the timing case houses the lifters and the camshaft lower bearing saddles. Note that one bolt, on the right side of the vehicle, is longer and retains the shaft for the upper timing chain tensioning rail.
2. Remove the coolant pipe that runs along the left rear of the block. Remove one bolt at the left front of the block that is located outside the camshaft cover. Then, go along in the area under the camshaft cover and remove all the remaining bolts for the timing case. Remove the timing case.
3. Remove the hex bolts fastening the head to the block at the front. These are located outside the camshaft cover and just behind the water pump drive belt. Then, using three loosening steps, remove the head bolts located under the camshaft cover in reverse order of the cylinder head torque sequence.

Fig. Cylinder head bolt torque sequence-S14 engine

To install:

1. BMW does not recommend machining the head. Make checks of the lower cylinder head and block deck surface to make sure they are true. Clean both cylinder head and block sealing surfaces thoroughly. Lubricate the head bolts with a light coating of engine oil. Make sure there is no oil or dirt in the bolt holes in the block. Install a new head gasket, making sure all bolt, oil, and coolant holes line up. Install the bolts as follows:
   1. Step 1: Torque following the tightening sequence to 36.8-38.3 ft. lbs. (50-52 Nm).
   2. Step 2: Torque following the tightening sequence to 57-60.4 ft. lbs. (80-82 Nm).
   3. Step 3: Wait 15 minutes, then torque in sequence to 73.7-75.2 ft. lbs. (100-102 Nm).

   
   
2. Be sure to reinstall the bolts that go outside the cylinder head cover and fasten the front of the head to the block at front and rear.
3. BMW recommends checking the fit of each tappet in the timing case, by performing the following procedure:
   1. Measure a tappet's outside diameter with a micrometer. Then, zero an inside micrometer at this exact dimension.
   2. Then, use the inside micrometer to measure the tappet bore that corresponds to this particular tappet. If the resulting measurement is 0.0001-0.0026 inch the tappet may be reused. If it is worn past this dimension, replace it with a new one. If the tappet is being replaced, repeat steps a and b to make sure it will now meet specifications. If the bore were to be worn so much that even a new tappet would not restore clearance to specification, it would be necessary to replace the timing case.
   3. Repeat for all the remaining tappets. Make sure to measure each tappet and its corresponding bore only.

   
   
4. The remaining steps of installation are the reverse of the removal procedure. Note the following:
5. Before remounting the timing case, replace the O-ring in the oil passage located at the left front of the block. Also, check the O-rings in the tops of the spark plug bores and replace these as necessary.
6. Install the timing case and torque the bolts in several stages. The smaller (M7) bolts are torqued to 10-12 ft. lbs. (14-16 Nm); the larger (M8) bolts are torqued to 14-15 ft. lbs. (19-21 Nm). Install each tappet back into the same bore.
7. When bolting the exhaust pipes to the flange at the manifold, use new gaskets and self-locking nuts and torque the nuts to 36 ft. lbs. (48 Nm).
8. When reinstalling the intake manifold, check and, if necessary, replace the O-rings where the manifold tubes connect to the throttle necks. Torque the nuts to 71 inch lbs. (8 Nm).
9. Fill the cooling system with the proper mixture of coolant and bleed as necessary.
10. Check and top off all fluid levels as needed.

S54 Engines

Fig. Remove the connector strip in sequence 1 to 6

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   WARNING

   The connector strip may break if tool No 12-1-120 is not used.
   
   
   
   NOTE

   The cylinder head bolts must be replaced.
   
   
   
   
   Negative battery cable

   Both exhaust manifolds

   Intake filter housing and mass air sensor

   Cylinder head cover

   All spark plugs

   Intake manifold

   Camshafts

   Raise rocker arms

   Adjustment plates using magnetic tool No. 11-4-400, set all aside in order

   Connector strip in sequence 1 to 6 with tool No. 12-1-120
   
   
   
   
   Press lock and detach supplementary air line

   Bracket for idle speed control valve from return valve and secure aside

   Temperature sensor connector

   Thermostat housing

   Electrical and vacuum connections from the end of the cylinder head

   Pull rod and fasteners securing the pipe under it

   Coolant return hose

   Fasteners from fuel feed line on the engine block

   Fuel feed line retaining clips

   Pull fuel feed line downwards

   Thrust bearing flange on the end of the cylinder head

   Sliding rail in the cylinder head

   Two bolts between the cylinder head and timing case cover, and the cable holder

   Cylinder head bolts from outside to inside in sequence, 14 to 1

   Cylinder head
   
   

To install:

Fig. Cylinder head bolt sequence on S54 engines

1. Thoroughly clean all mounting surfaces and check the head for warpage. Take care not to drop any pieces of gasket or debris into the oil or coolant passages. Check the condition of the head locating dowel sleeves and clean out the bolt threads with a tap.
2. Mount the cylinder head on the block and use new bolts. Do not remove the coating on the head bolts. Apply oil to the threads and washer contact area. Torque following the tightening sequence as follows:
   1. Step 1: 22 ft. lbs. (30 Nm).
   2. Step 2: 90 degrees.
   3. Step 3: 90 degrees.

   
   
3. The balance of installation is the reverse of the removal procedure. Be sure to replace all seals and O-rings.
4. Fill the cooling system.
5. Start the engine and check for leaks.
   
   NOTE

   It may be necessary to bleed the cooling system a second time after the engine has been started.
   
   

S62 Engines
Left Side

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Left exhaust manifold

   Intake filter housing and mass air sensor

   Intake manifold

   Both cylinder head covers

   All spark plugs

   Fan clutch with impeller and cowl

   Pulse generator connectors

   Cable channel and bracket

   Throttle actuator

   Hose from supplementary air distributor

   Knock sensor cable guide from the return line

   Coolant hoses from the block and both return hoses on the heads

   Brake booster hose

   Vacuum hose from pressure regulator

   Oil lines on both cylinder heads

   Pulse generators on the end of the cylinder head
   
   
5. Hold the camshafts on the hexagon heads provided and remove the banjo bolts securing the signal rings.
6. Rotate the crankshaft in the direction of rotation to the Top Dead Center (TDC) firing position of cylinder 1. Secure the vibration damper in place. This can be done with tool No. 11-2-300.
7. Remove the oil line from the VANOS unit. Fit an air line adapter to the hole and apply 30-115 psi (2-8 bar) of compressed air.
8. Unplug the solenoid and connect tool No. 12-6-050 and 12-6-411 to the VANOS unit. Toggle the buttons 4 and 3 several times.
   
   
   

   

   Fig. Special tools connected to the VANOS unit

9. Press and hold down button 4 while rotating the intake camshaft against the direction of travel as far as it will go.
10. Press buttons 2 and 1 several times.
11. Press and hold button 2 while rotating the exhaust camshaft against the direction of rotation as far as it will go.
12. Remove the tool securing the vibration damper and rotate the crankshaft in the direction of rotation one revolution to overlap the TDC position.
13. Loosen the 6 accessible bolts on the cam sprockets two turns.
14. Rotate the crankshaft in the direction of rotation until cylinder 1 is in the TDC position. Secure the vibration damper from rotating again.
15. Loosen the 6 remaining bolts on the cam sprockets two turns.
16. Align the camshaft opening to the locating bores in the bearing caps and secure in position. Tool No. 11 7 120 can be used for this.
17. Remove the fasteners securing the VANOS unit and remove it from the cylinder head. Be sure to remove the compressed air first.
18. Remove the tool securing the vibration damper.
    
    WARNING

    No piston must be in the TDC position when the cylinder head is removed.
    
    
    
    NOTE

    When the VANOS unit is removed, the chain sprockets of the camshafts are not positively connected to the camshafts. Camshafts on cylinder bank 5 to 8 do not rotate.
    
    
19. Rotate the crankshaft against the direction of rotation to 45 degrees BTDC.
20. Remove or disconnect the following:
    
    
    Thermostat

    Left timing case cover.

    Chain tensioning piston

    The slackened bolts from the spacer ring and remove the ring

    Spline hub with plate spring and supporting ring. Keep note of the direction the plate spring faces

    Intake chain sprocket from the centering sleeve. Keep the chain tensioned and secure from slipping into the lower timing cover

    Sliding rail from the cylinder head

    Cylinder head bolts in sequence from 10 to 1

    Cylinder head
    
    

To install:

Fig. Cylinder head bolt sequence on S62 engines

1. Thoroughly clean all mounting surfaces and check the head for warpage. Take care not to drop any pieces of gasket or debris into the oil or coolant passages. Check the condition of the head locating dowel sleeves and clean out the bolt threads with a tap.
2. Coat the joint between the engine block and timing case cover with Drei Bond 1209.
3. Mount the cylinder head on the block and use new bolts. Do not remove the coating on the head bolts. Apply oil to the threads and washer contact area. Torque following the tightening sequence as follows:
   1. Step 1: 22 ft. lbs. (30 Nm).
   2. Step 2: 80 degrees.
   3. Step 3: 80 degrees.

   
   
4. Install the slide rail. Install the chain sprocket and chain on the centering sleeve. Do not secure it with fasteners. Note that the bores of the chain sprocket do not have to line up with the thread holes yet.
5. Install the chain tensioning piston. If the old one is being reused, drain the oil from it.
6. Rotate the crankshaft in the direction of rotation to the TDC position again. Secure the vibration damper. Be sure to keep the intake sprocket from slipping off the centering sleeve.
7. Check the position of the chain sprocket. If the threads are not visible through the holes, pull the sprocket from the sleeve (while keeping the chain tensioned), and refit. Fine adjustment can be made by rotating the exhaust side.
   
   NOTE

   On engines manufactured up to 9/2001, the plate spring points in the direction of the supporting ring. On engine built after 9/2001, it faces towards the spline hub.
   
   
8. Install the spline hub with the plate spring and supporting ring. Align the hub so the oil pump is positioned as pictured.
   
   
   

   

   Fig. Spline hub (1), plate spring (2), and supporting ring (3)-version up to 9/2001

   
   
   
   

   

   Fig. Spline hub (1) position

9. Fit the spacer ring and install the bolts snug. Slacken the bolts until the spline hub can be moved.
10. Install the left timing case cover.
11. Replace the seals on the VANOS unit. Coat the seals and gears with oil.
12. Connect tool No. 12-6-050 and 12-6-411 to the VANOS unit. Press buttons 2 and 4. Push the splined shafts by hand into the VANOS unit.
13. Turn the splined hubs of the intake and exhaust camshafts clockwise to the right limit positon.
14. Attach the VANOS unit. Rotate the splined shafts until the spur tooting is engaged. Push the VANOS unit into the gear until the helical cut splines are positioned shortly before meshing with the spline hub.
15. If the gears on the exhaust side cannot be pushed into the splined hub, rotate the hub against the direction of rotation until correctly positioned. Do not rotate any further. Do the same for the intake side.
16. Align the oil pump to the holes in the spline hub. Push the VANOS unit in until the seals just rest against the timing cover. If necessary, realign the oil pump drive to the spline hub.
17. Insert one bolt on each side finger tight.
18. Use tool No. 11 7 200 to secure the timing sprockets. Tighten the six accessible bolts to 7 ft. lbs. (10 Nm). Then slacken all the bolts a quarter of a turn.
19. Install all the bolts on the VANOS unit. Alternately tighten them in half turn increments evenly until the unit rests against the timing cover.
20. Remove the tool securing the vibration damper. Make sure the timing sprockets are still secured to allow the camshafts to remain locked in position. Carefully rotate the engine against the direction of rotation until there is resistance and the spline hubs are at the stop.
21. Rotate the crankshaft in the direction of rotation until cylinder 1 is at TDC. Secure the vibration damper again.
22. Tighten the six accessible bolts on the timing sprockets to 7 ft. lbs. (10 Nm).
23. Remove tool No. 11-7-200. Remove the tool securing the vibration damper and turn the crankshaft in the direction of rotation on revolution to overlap the TDC position. Hold the sprockets with tool No. 11-7-200, and tighten the six remaining bolts on the timing sprockets to 7 ft. lbs. (10 Nm).
24. Rotate the crankshaft in the direction of rotation until cylinder 1 is at TDC of the firing position. Secure the vibration damper again.
25. Install the signal rings. The intake camshaft ring has one dowel pin. Tighten to 37 ft. lbs. (50 Nm).
26. Remove the oil line from the VANOS unit on cylinder bank 1 to 4. Fit an air line adapter to the hole and apply 30-115 psi (2-8 bar) of compressed air.
27. Unplug the solenoid and connect tool No. 12-6-050 and 12-6-411 to the VANOS unit. Toggle the buttons 1 and 2 several times.
28. Press and hold down button 1 while rotating the intake camshaft against the direction of travel as far as it will go.
29. Press buttons 3 and 4 several times.
30. Press and hold button 3 while rotating the exhaust camshaft against the direction of rotation as far as it will go.
31. Remove the tool securing the vibration damper and rotate the crankshaft in the direction of rotation two revolutions to the cylinder 1 TDC firing position. Secure the vibration damper.
32. Check the camshaft adjustment. The groove in the camshaft must be inside the groove on the first bearing cap. If necessary, adjust the camshaft timing.
    
    
    

    

    Fig. The groove in the camshaft must be inside the groove on the first bearing cap

33. The balance of installation is the reverse of the removal procedure.
34. Fill the cooling system.
35. Start the engine and check for leaks.
    
    NOTE

    It may be necessary to bleed the cooling system a second time after the engine has been started. A rattling noise may be heard in the VANOS unit until oil pressure has built up and air has vented.
    
    

Right Side

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Right exhaust manifold

   Intake filter housing and mass air sensor

   Intake manifold

   Wiring harness from heads and secure aside

   Fuel line with injectors

   Idle speed control valve

   Hoses from supplementary air distributor to tank venting valve and throttle

   Hoses to solenoid valve

   Coolant hoses from the block and both return hoses on the heads

   Brake booster hose

   Pull rod from throttle actuator

   Both cylinder head covers

   All spark plugs

   Fan clutch with impeller and cowl

   Thermostat

   Cable channel and bracket

   Throttle actuator

   Hose from supplementary air distributor

   Knock sensor cable guide from the return line

   Vacuum hose from pressure regulator

   Oil lines on both cylinder heads

   Pulse generators on the end of the cylinder head
   
   
5. Hold the camshafts on the hexagon heads provided and remove the banjo bolts securing the signal rings.
6. Rotate the crankshaft in the direction of rotation to the TDC firing position of cylinder 1. Secure the vibration damper in place. This can be done with tool No. 11-2-300.
7. Remove the oil line from the VANOS unit. Fit an air line adapter to the hole and apply 30-115 psi (2-8 bar) of compressed air.
8. Unplug the solenoid and connect tool No. 12-6-050 and 12-6-411 to the VANOS unit. Toggle the buttons 1 and 2 several times.
9. Press and hold down button 1 while rotating the intake camshaft against the direction of travel as far as it will go.
10. Press buttons 3 and 4 several times.
11. Press and hold button 3 while rotating the exhaust camshaft against the direction of rotation as far as it will go.
12. Remove the tool securing the vibration damper and rotate the crankshaft in the direction of rotation one revolution to overlap the TDC position.
13. Loosen the 6 accessible bolts on the cam sprockets two turns.
14. Rotate the crankshaft in the direction of rotation until cylinder 1 is in the TDC firing position. Secure the vibration damper from rotating again.
15. Loosen the 6 remaining bolts on the cam sprockets two turns.
16. Align the camshaft opening to the locating bores in the bearing caps and secure in position. Tool No. 11 7 120 can be used for this.
17. Remove the fasteners securing the VANOS unit and remove it from the cylinder head. Be sure to remove the compressed air first.
18. Remove the tool securing the vibration damper.
    
    WARNING

    No piston must be in the TDC position when the cylinder head is removed.
    
    
    
    NOTE

    When the VANOS unit is removed, the chain sprockets of the camshafts are not positively connected to the camshafts. Camshafts on cylinder bank 1 to 4 do not rotate.
    
    
19. Rotate the crankshaft against the direction of rotation to 45 degrees BTDC.
20. Remove or disconnect the following:
    
    
    Chain tensioning piston

    Left timing case cover.

    The slackened bolts from the spacer ring and remove the ring

    Spline hub with plate spring and supporting ring. Keep note of the direction the plate spring faces

    Intake chain sprocket from the centering sleeve. Keep the chain tensioned and secure from slipping into the lower timing cover

    Cylinder head bolts in sequence from 10 to 1

    Cylinder head
    
    

To install:

1. Thoroughly clean all mounting surfaces and check the head for warpage. Take care not to drop any pieces of gasket or debris into the oil or coolant passages. Check the condition of the head locating dowel sleeves and clean out the bolt threads with a tap.
2. Coat the joint between the engine block and timing case cover with Drei Bond 1209.
3. Mount the cylinder head on the block and use new bolts. Do not remove the coating on the head bolts. Apply oil to the threads and washer contact area. Torque following the tightening sequence as follows:
   1. Step 1: 22 ft. lbs. (30 Nm).
   2. Step 2: 80 degrees.
   3. Step 3: 80 degrees.

   
   
4. Install the chain sprocket and chain on the centering sleeve. Do not secure it with fasteners. Note that the bores of the chain sprocket do not have to line up with the thread holes yet.
5. Rotate the crankshaft in the direction of rotation to the TDC position again. Secure the vibration damper. Be sure to keep the intake sprocket from slipping off the centering sleeve.
6. Check the position of the chain sprocket. If the threads are not visible through the holes, pull the sprocket from the sleeve (while keeping the chain tensioned), and refit. Fine adjustment can be made by rotating the exhaust side.
   
   NOTE

   On engines manufactured up to 9/2001, the plate spring points in the direction of the supporting ring. On engine built after 9/2001, it faces towards the spline hub.
   
   
7. Install the spline hub with the plate spring and supporting ring. Align the hub so the oil pump is positioned as pictured.
8. Fit the spacer ring and install the bolts snug. Slacken the bolts until the spline hub can be moved.
9. Install the right timing case cover.
10. Replace the seals on the VANOS unit. Coat the seals and gears with oil.
11. Connect tool No. 12-6-050 and 12-6-411 to the VANOS unit. Press buttons 1 and 3. Push the splined shafts by hand into the VANOS unit.
12. Turn the splined hubs of the intake and exhaust camshafts clockwise to the right limit positon.
13. Attach the VANOS unit. Rotate the splined shafts until the spur tooting is engaged. Push the VANOS unit into the gear until the helical cut splines are positioned shortly before meshing with the spline hub.
14. If the gears on the exhaust side cannot be pushed into the splined hub, rotate the hub against the direction of rotation until correctly positioned. Do not rotate any further. Do the same for the intake side.
15. Align the oil pump to the holes in the spline hub. Push the VANOS unit in until the seals just rest against the timing cover. If necessary, realign the oil pump drive to the spline hub.
16. Insert one bolt on each side finger tight.
17. Use tool No. 11 7 200 to secure the timing sprockets. Tighten the six accessible bolts to 7 ft. lbs. (10 Nm). Then slacken all six a quarter turn.
18. Install all the bolts on the VANOS unit. Alternately tighten them in half turn increments evenly until the unit rests against the timing cover.
19. Remove the tool securing the vibration damper. Make sure the timing sprockets are still secured to allow the camshafts to remain locked in position. Carefully rotate the engine against the direction of rotation until there is resistance and the spline hubs are at the stop.
20. Rotate the crankshaft in the direction of rotation until cylinder 1 is at TDC. Secure the vibration damper again.
21. Tighten the six accessible bolts on the timing sprockets to 7 ft. lbs. (10 Nm).
22. Remove tool No. 11-7-200. Remove the tool securing the vibration damper and turn the crankshaft in the direction of rotation on revolution to overlap the TDC position. Hold the sprockets with tool No. 11-7-200, and tighten the six remaining bolts on the timing sprockets to 7 ft. lbs. (10 Nm).
23. Rotate the crankshaft in the direction of rotation until cylinder 1 is at TDC of the firing position. Secure the vibration damper again.
24. Install the signal rings. The intake camshaft ring has one dowel pin. Tighten to 37 ft. lbs. (50 Nm).
25. Remove the oil line from the VANOS unit on cylinder bank 5 to 8. Fit an air line adapter to the hole and apply 30-115 psi (2-8 bar) of compressed air.
26. Unplug the solenoid and connect tool No. 12-6-050 and 12-6-411 to the VANOS unit. Toggle the buttons 4 and 3 several times.
27. Press and hold down button 4 while rotating the intake camshaft against the direction of travel as far as it will go.
28. Press buttons 2 and 1 several times.
29. Press and hold button 2 while rotating the exhaust camshaft against the direction of rotation as far as it will go.
30. Remove the tool securing the vibration damper and rotate the crankshaft in the direction of rotation two revolutions to the cylinder 1 TDC firing position. Secure the vibration damper.
31. Check the camshaft adjustment. The groove in the camshaft must be inside the groove on the first bearing cap. If necessary, adjust the camshaft timing.
32. The balance of installation is the reverse of the removal procedure.
33. Fill the cooling system.
34. Start the engine and check for leaks.
    
    NOTE

    It may be necessary to bleed the cooling system a second time after the engine has been started. A rattling noise may be heard in the VANOS unit until oil pressure has built up and air has vented.