Honda Bmw 5 Service Manual

							
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.