Honda Bmw 5 Service Manual

							
Cylinder Head Removal and Installation I 
Remove cylinder head cover mounting studs  (arrows) from 
center  of cylinder head. 
- Remove  crankshaft loclting tool from transmission  bell hous- 
Ing. 
Lift primary chain and hold under tension, then  rotate engine 
at  vibration damper in opposite direction  of normal rotation 
(counterclocltwise)  approximately 30. 
CAUTION- 
By turning crankshait3O0, pistons are movedaway  from top 
dead  center,  to prevent possible  valve interference  to pistons 
during camshaft  servicing. 
- Remove camshaft loclting  tools (BMW special tool set 11 3 
240) from  rear  of cylinder  head. 
4 Remove camshaft bearing cap 1 on intake camshaft. 
4 Fit BMW  special tools 11 3 260 (A) and 11 3 270 (B) to  cyl- 
inder head  and screw long bolts  (arrows) into spark  plug 
threads. Tensioning  pins on tool will align with the bearing 
caps  on the 
intake camshaft. 
CAUJION- 
Do not  over torque  bolts into  sparkplug  holes.   
						

							
11 3-38 
I Cylinder Head Removal and Installation 
< Turn eccentric shaft  of special  tool to pretension  intake cam- 
shaft bearing  caps. Remove nuts  on all intake  camshaft  bear- 
ing  caps. 
- Slowly  release tension  on eccentric shaft  and remove BMW 
spec~al tools.  Remove  bearing caps and  set as~de in order. 
Remove  camshaft and store  safely. 
- Repeat procedure for exhaust  camshaft. 
4 Secure hydraulic  lifters in lifter bores using  BMW speclal tool 
11 3 250, or remove lifters using  a magnetic  pick-up tool. 
With lifters secure  or removed,  lift out  camshaft bearing car- 
riers  from  cylinder head. 
Use  care  to not  let hydraulic lifters fall out as  camshaft car- 
rier  is removed. 
Hydraulic lifters  should be stored 
ln an uprightpositlon. 
Used  hydraulic lifters must  be reinstalled  into their  orig- 
inal  lifter  bores. 
4 Remove  intake camshaft position sensor (arrow) from side 
of  cylinder head. 
4 Remove  secondary chain lowerguide bolts (arrow). Remove 
chain  guide.   
						

							
. - -- - 
Cylinder Head Removal  and Installation -- 
Remove bolts  (arrows) holding timing chain  cover to cylinder 
head.  (Photo  shows camshafts  and camshaft  bearing caps in 
place). 
4 Using BMW special  tool 11 2 250 or equivalent,  loosen cylin- 
der  head  bolts in several  stages,  in sequence shown.  Discard 
head  bolts. 
NOJE- 
BMW special  tool 11 2 250 is a thin-walled  Torx El2 socket 
with an extended reach. The cylinder  head bolts are re- 
cessed into  the head below the 
camshaft towers  with  little 
working space. 
- Lift  off cylinder head.  Refer to 116 Cylinder  Head and Val- 
vetrain for cylinder  head reconditioning information. 
Cylinder head, installing, M52 TU and M54 
engines 
Clean  cylinder  head and gasket  surfaces  of cylinder bloclc 
and  all  timing chain  covers. 
CAUTION-  Remove  foreign matter  and liquid  from bolt holes.  Trapped  oil 
or  coolant  in bolt holes  can cause damage  to 
blocl~, 
CAUJION- 
Do not  use  a metal  scraper  or wire  brush  to clean  the alumi- 
num  cylinder  head or pistons.  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. 
Evaluate cylinder  head as shown  in 
116 Cylinder  Head and 
Valvetrain. 
NOTE-  If the cylinder  head has been machined,  a special  0.3 
mm 
(0.01 1 in.) thicker gasket should  be installed. The thicker 
gasket  is available  from an authorized 
BMW dealer  and 
should be  marked accordingly 
Cylinder  head and valve  specifications  are covered in 116 
Cylinder  Head and Valvetrain.   
						

							
11 3-40 
I Cylinder Head Removal  and Installation 
Lubricate  camshafts,  camshaft carriers, bearing caps, hy- 
draulic lifters,  friction washers,  splined shafts and spline  hubs 
with  assembly lubricant before installation. 
4 Check that two cylinder  head aligning  sleeves (arrows) are 
correctly  positioned  in block  and are not damaged. 
- Apply  elastic sealing compound  Three Bond 1209 8 to cor- 
ner  joints  on  cylinder block to timing chain cover. 
- Place  new cylinder  head gasket  on  cylinder  block. 
NOTE- 
The word OBEN or TOP  printed on  the gasket, should 
face  up. The cylinder  headgaslet  will fit correctly in only one 
orientation. 
- Set cylinder  head in position, guiding primary  chain through 
cylinder  head opening. 
CAUJION- 
Make  sure the crankshaft, which had  been rotated approxi- 
mately  30 opposite the direction  of engine  rotation from 
TDC,  is still  in thatposition  before lowering  the cylinder head 
into  position. All  pistons must be out  of TDC  position  to pre- 
vent 
valve/piston interference  when the camshafts are in- 
stalled. 
- Lightly lubricate new cylinder  head bolts and washers  with 
oil.  Install bolts  and washers finger  tight. Install  cylinder  head 
to  lower  timing chain  cover bolts finger  tight. 
NOJE- 
Cylinder head bolts  should not be reused.  They are 
stretch-type bolts  and must  be replaced  whenever loos- 
ened. 
* Aluminum  cylinder  blocls use different length cylinder 
head  bolts and torque  values than cast iron  blocks. 
Check that  all washers  for 
Nle head bolts are in place  be- 
fore installing  the bolts.  Some of the washers  may be 
staked  to the cylinder head. 
I 12 10 4 2 6 8 141 Tighten  cylinder  head bolts in correct sequence  (1-14) 
CA U TIOW- 
The bolts  should be  tightened in three stages  as listed  below 
The final stages  require the use of a BMW special  tool 
11 2 
110 or a suitable protractor  to tighten  the bolts  to a specified 
torque angle.   
						

							
. - .. 
Cylinder Head Removal  and installation] -- 
- Secure cylinder head bolts  by torquing  an additional 90 
each  for Stage 2 and 3. 
Tightening torques 
Cylinder  head to engine  block 
(aluminum  block) 
Stage 
1 40  Nm  (30 it-lb) 
Stage 2 +90° 
Stage  3 80 
4 lnstall intake camshaft  position  sensor (arrow). 
4 Install lower secondary chain  guide. Tighten tom bolts to 
specifications.  The bolt on the intake camshaft  side is long 
and  extends  into the engine block. 
4 Install and tighten cylinder  head-to-lower timing chain cover 
bolts  (arrows).  (Photo shows camshafts  in place). 
Tightening torque  Secondary chain  guide to cylinder head 
10 Nm (89 in-lb) 
Cylinder  head to lower timing  chain cover 
M6 10 Nm (89 in-lb) 
M7 15 Nm (1 1 it-lb)   
						

							
1 13-42 
I Cylinder Head Removal and Installation 
4 Before installing camshaft carriers, examine bearing points 
(arrows)  on hydraulic  lifter bores  for signs  of wear. 
4 Center camshaft carrier with  hydraulic lifters on pins (ar- 
rows)  at bearing positions 2 and 7. 
Note marks on carriers: (E) for intake side  and (A) for exhaust 
side. 
Lift  timing chain and put exhaust cam onto  exhaust camshaft 
carrier. Place intake  camshaft on camshaft  carrier.   
						

							
.- 
Cylinder Head Removal  and Installation 
4 Rotate  camshafts  until intake  and exhaust  lobes  for cylinder 
1 face  each  other  (arrows). 
CAUTION- 
Be sure  that cranlcshaft is stillpositioned  at least 30 away 
from 
TDC. 
- Place bearing  caps on cams,  but do not install  retaining nuts. 
4 Fit BMW special tool 11 3 260 (A) and 11 3 270 (B) to cylin- 
der head over  intake camshaft  and screw  long bolts  (arrows) 
into spark  plug threads. 
CAUTIOI\C 
Do not overtighten bolts  in spark plug holes. 
Turn  eccentric  shaft of special  tool to pretension 
bearing 
caps.  Install  and torque  nuts on intake camshaft  bearing 
caps. 
Tightening torque Camshaft  bearing 
cap to cylinder  head (M7) 14 Nm (10 ft-lb) 
Release tension  on eccentric 
shaft and remove BMW special 
tools 
11 3 2601270. 
Repeat procedure  for exhaust  camshaft. 
CAUTION- 
After the camshafts are installed,  a minimum waiting time is 
required for  the hydraulic lifters to  bleed down before  bring- 
ing the crankshaft  andpiston back to top 
deadcenter. When 
the camshafts are  removed, the hydraulic  lifters can  expand. 
This expansion  can cause increased  valve lift when  the cam- 
shafts  are bolted down,  possibly resulting  in piston  interfer- 
ence. 
Crankshaft 
I valve  timing waiting  times 
68.F (20°C) and higher 4 minutes 
50-68F(10-20°C) 11 minutes 
32-5O0F(O-10°C) 30 minutes   
						

							
11 3-44 
I Cylinder Head Removal and Installation 
4 Secure camshafts  in TDC position using BMW special tool 
set 
11 3 240. 
4 In  necessary,  turn camshaft slightly so that  special tools  are 
squarely  seated on cylinder  head. 
4 Lift timing  chain and hold  under tension.   
						

							
Cylinder Head Removal  and Installation 
4 While maintaining  tension on timing chain, rotate crankshaft 
at  vibration damper from 
30 before TDC in direction  of rota- 
tion  (clockwise) until number 
1 cylinder  is  at TDC position 
with  line between  the 
OIT (arrow) on front  pulley lined up 
with  boss  on lower timing chain  cover.   
						

							
1 13-46 
Cylinder  Head Removal and Installation 
Double 
VANOS Timing 
Chain Components 
1.  Impulse  wheel mounting  nut 
2.  Exhaust  camshaft impulse 
wheel 
3. Spring  plate, exhaust 
4.  Thrust  spacer (T 
= 3.5 mm) 
5. Splined  shaft 
6. Torx screw 
7. Exhaust camshaft secondary 
sprocket 
8.  Secondary  timing chain 
9.  Splined  sleeve 
10.  Primary  sprocket 
11.  Threaded  locating stud 
12.  Secondary  chain tensioner 
13.  Secondary  chain lower guide 
14.  Sprocket  mounting  nut 
15.  Spring  plate, intake 
16.  Splined  shaft 
17.  lntakecamshaft  sprocket 
18.  Locating  stud 
19.  Thrust  spacer 
20.  Intake  camshaft impulse  wheel 
Double VANOS timing chain components, 
installing, 
M52 TU  and M54 engines - 
4 Slide  impulse  wheel on intake camshaft,  aligning  boss with 
raised  portion  on camshaft 
(arrow).