| Disconnect negative cable from battery in trunk. |
 |
| Hold water pump pulley (green arrow) with BMW special tool 11
5 030, or with a large set of "water pump" pliers. |
 |
| Remove fan (yellow arrow above) with BMW special tool 11 5 040
or similar slim 32mm wrench. |
| An alternative to using pliers is to install the wrench and
strike wrench sharply with a hammer in a clockwise direction. |
CAUTION: Left hand thread, turn wrench as if to tighten a regular bolt, to remove the fan.
|
Remove splash shield below front of engine.
|
| Drain coolant from cylinder block drain plug on right side of block,
behind exhaust manifold and radiator drain plug on lower left corner, or center, of
radiator. |
 |
 |
| Loosen clamp on intake hose at airflow meter (yellow arrow).
Disconnect altitude sensor and air flow meter (blue arrows). Loosen two 10mm nuts
retaining air filter housing (green arrows) and remove the assembly. |
 |
| Loosen clamp on intake boot, remove wiring from clips on boot
and remove from air box. |
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| Disconnect accelerator cable and cruise cable if fitted, by
squeezing plastic tabs together and pulling retainer from bracket (blue arrow).
Remove nuts (green arrows) holding cable bracket to intake air box. Place cables, still in
bracket, aside. |
 |
| Remove vacuum hose to brake booster from intake manifold (blue
arrow), remove nut clamping hose to intake manifold (green arrow). Fold hose back out of
way. Aluminum fitting will often pull out of intake manifold. Clean fitting and
hole, apply Loctite to fitting and re-install. |
 |
| Remove hose from fitting on bottom of air box (yellow arrow).
Unscrew nut on brace below air box (green arrow). |
 |
| Remove hose from front of intake manifold beside number 1 throttle body.
Remove nuts attaching air box to throttle bodies, remove air box. |
 |
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| Remove supply and return hoses from coolant reservoir. |
 |
| Remove coil wire from coil, unplug temp sensors on coolant
manifold on right side of engine, near oil fill cap. Remove 10mm nut retaining harness to
distributor housing. |
 |
| Remove upper radiator hose completely and remove thermostat
hose from coolant manifold at right side of engine. |
 |
Remove harness from support across front of head.
|
 |
| Pull off vacuum line from junction between numbers 1 and 2
throttle bodies. Remove upper hose from idle valve. Disconnect other idle valve hose from
fitting between numbers 3 and 4 throttle bodies. Remove idle valve from rubber holder.
Remove engine harness from holder located behind idle valve position. |
 |
| Lever up injector harness, disconnect idle valve extension
harness (green arrow) and pull injector harness out from between fuel pressure regulator
and cylinder head. |
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| Disconnect throttle position sensor. |
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| Remove purge hose from rear left of valve cover. |
 |
| Remove two 10mm bolts securing fuel rail to manifold (one
pictured, green arrow) and pull injectors out of manifold. Remove vacuum line
(yellow arrow) from fuel pressure regulator. Vacuum hose will more than likely need to be
cut off. Replace hose on re-assembly. |
 |
| Remove heater hose from rear of cylinder head. |
 |
| Remove nut retaining engine harness to number 4 throttle body,
place harness to the side. |
 |
| Remove the two 10mm nuts retaining coolant bypass pipe to the
left side of the head. Remove the hose from the nipple at the front of the head and move
the pipe aside. |
 |
| Remove distributor cap by loosening the 8mm bolts that are
securing it. Some cars may have a cover that is secured by 3mm Allen bolts, remove cover,
then cap. |
 |
| Remove nuts holding spark plug harness to valve cover, remove
spark plug boots and place harness aside. |
 |
| Remove distributor rotor by loosening the three 3mm Allen
bolts. As with cap, bolts are captive and do not have to be fully removed to remove the
component. |
 |
| Remove 6mm Allen bolt from DME adapter and pull adapter from
end of camshaft. |
 |
| Remove distributor housing from right side of head, and cover
from left side of head. |
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| Remove the eighteen 10mm nuts securing valve cover. |
 |
Lift off valve cover.
|
|
| Remove the end cover at rear of head. (six 10mm bolts) |
 |
| Rotate crankshaft until cylinder number 1 is on TDC. Take note of
camshaft location, there are marks on the rear of the front caps, and on the cams. |
 |
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| Remove upper timing chain guide rail. |
 |
| Remove the timing chain tensioner plug from the right side of
the cylinder head |
 |
CAUTION: Plug is under considerable spring tension!
|
| Remove timing chain tensioner spring and piston. |
|
| Open lock plates and unscrew timing chain gears |
 |
CAUTION: Never turn crankshaft with timing chain
loose or removed.
|
| Loosen the cam bearing caps very gradually,
take your time, it costs less than a new camshaft. |
 |
| Mark camshafts as intake and exhaust and remove from cylinder
head. Standard camshafts are identical, but should be installed in the same position they
are removed from. |
| Remove lifters and place in BMW special tool 11 3 030, which
is a piece of wood with 24 holes in it. Use anything you have handy to make sure the
lifters do not get mixed up. Used lifters MUST go back into the same
bore, or excessive wear will result. |
| Remove the five 5mm Allen head bolts around the front of the
head. Blue arrow depicts longer of 5 bolts. This bolt must be returned to this position on
re-assembly. |
 |
| Remove the sixteen 6mm Allen bolts (green arrows), eight 13mm
(yellow arrows) and 2 14mm (red arrows) nuts holding the cam carrier to the head, lift off
the carrier. Carrier is sealed to head with silicone sealer. It will take some work
to break it loose. |
 |
| Remove the two 10mm bolts securing coolant feed pipe to
cylinder head cooling pipe. Remove hose from water pump and move pipe aside. |
 |
| Remove cooling pipe from cylinder head in order to gain
clearance to exhaust manifold nuts. |
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| Remove bolts from exhaust manifold / exhaust pipe flange. |
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| Remove bolt from exhaust bracket at transmission. |
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| Remove the sixteen 9mm nuts from the exhaust manifold. |
 |
| Remove the two 5mm Allen head bolts from front of cylinder
head. |
 |
| Remove head bolts in order shown. Break the torque on all
bolts, then remove them. |
 |
Lift off cylinder head, complete with intake manifold. There
is no need to remove the intake manifold before removing the head.
|
Installation:
|
|
| Check cylinder head surface with a straight edge. Machine head
surface if necessary. BMW does not recommend machining head surface. Stock cylinder head
height is 96.0mm ± 0.03 (3.7795 ± 0.0012") |
| Measure all lifter bores and lifters for 0.0025 to 0.066mm
(0.0001 to 0.0026 inches ) clearance. |
| Clean surface of cylinder block with a razor scraper. Remove
all traces of old gasket. |
| Clean all cylinder head bolt holes. Lubricate new bolts with a
light coat of engine oil. If there is any fluid in the bottom of the head bolt holes, you
risk cracking the block when tightening the head bolts. |
| Place cylinder head gasket on cylinder block. Place a
small amount of hi-temp silicone sealer in the two holes in the gasket where the cylinder
block meets the timing cover. |
 |
| Torque cylinder head to specification in correct order. |
 |
| Replace O ring in oil bore by first intake valve. |
 |
| Replace O rings around spark plug openings. |
 |
| Install the five 5mm Allen bolts in front of cylinder head,
the longer of the 5 bolts must be placed in the right front corner (blue arrow), it
extends below the level of the cam carrier to retain the shaft for the upper tensioning
rail. |
|
Replace O-rings on fuel injectors.
|
|
| Ensure correct positioning of idle control valve harness
bracket (green arrow) when installing fuel injector rail. Replace vacuum hose for fuel
pressure regulator. (yellow arrow) |
|
