11 31 034 Removing and installing/replacing right inlet camshaft (N62 to 9/03)

NOTE:

For Special Tool identification, see ENGINE- SPECIAL TOOLS - 5-SERIES (E60) .

Special Tools Required:

11 9 470
11 9 472
11 9 473
11 9 474
11 9 475
11 9 480
11 9 490

(cylinder bank 1 to 4)

Removal:

Removal of inlet camshaft is described separately from installation.

Remove servomotor for right eccentric shaft. Refer to 11 37 024 REMOVING AND INSTALLING/REPLACING SERVOMOTOR FOR RIGHT ECCENTRIC SHAFT (N62/N62TU) .

Remove ignition coils on cylinder bank 1 to 4.

Remove right cylinder head cover. Refer to 11 12 006 REMOVING AND INSTALLING/SEALING RIGHT CYLINDER HEAD COVER (N62/N62TU) .

Remove spark plugs on cylinder bank 1 to 4.

Remove inlet and exhaust adjustment unit on right side. Refer to 11 36 048 REMOVING AND INSTALLING/REPLACING INLET AND EXHAUST ADJUSTMENT UNITS ON RIGHT SIDE (N62/N62TU) .

IMPORTANT: The inlet camshaft must first be rotated so that when the bearing bracket is removed the intermediate levers do not slip out and damage the camshaft.

Rotate inlet camshaft in direction of rotation until cam on 1st cylinder is positioned horizontally as shown in illustration.

Fig 1: Identifying 1st Cylinder Cam Positioned Horizontally

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Rotate eccentric shaft at dihedral head as illustrated in order to reduce tension on torsion spring (1).

Pretension torsion spring (1) with a cable strap (2), feed out from roller (3) and carefully relieve tension.

Fig 2: Securing Torsion Spring

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Rotate eccentric shaft at dihedral head as shown in illustration back to minimum stroke position.

Fig 3: Aligning Eccentric Shaft

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IMPORTANT: Do not mix up the camshaft bearing covers of cylinders 1 to 4 and 5 to 8.

NOTE: Bearing caps of inlet camshaft are marked on cylinder bank 1 to 4 with L E1 to L E5 from inlet side.

Release nuts and remove bearing cap L E1.

Fig 4: Identifying Bearing Cap L E1

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Release 8 nuts of bearing bracket (1) from outside to inside.

Fig 5: Locating Bearing Bracket Nuts

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NOTE: Rocker arms are freely accessible after bearing bracket has been removed. Do "not" remove rocker arm (1) on inlet side.

IMPORTANT: Rockers arms (1) are divided into individual tolerance classes. The tolerance classes are designated as illustrated with the numbers from 1 to 4. Used rocker arms (1) may only be reused in the same position.

When replacing rocker arms (1) on inlet side: install rocker arms of the same tolerance class in the same position.

Fig 6: View Of Rocker Arms

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Clamp special tool 11 9 470 as illustrated in a vise.

Fig 7: Clamping Special Tool In Vise

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IMPORTANT: Do not tilt bearing bracket (1).

Carefully lift out bearing bracket (1).

Fig 8: View Of Bearing Bracket

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Place bearing bracket (1) with inlet camshaft and eccentric shaft as illustrated on special tool 11 9 470.

Secure bearing bracket (1) with a nut (special tool 11 9 473).

Fig 9: Securing Bearing Bracket With Nut

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IMPORTANT: The lower section of the bearing bracket (1) is machined with the cylinder head and must not be mixed up.

NOTE: Lower section of bearing bracket (1) remains on cylinder head.

Fig 10: Identifying Lower Section Of Bearing Bracket

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NOTE: This work step will only be necessary if after the inlet camshaft has been removed the eccentric shaft is also to be removed.

If necessary, remove eccentric shaft sensor (2).

Fig 11: Removing Eccentric Shaft Sensor

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NOTE: Removal of the intermediate levers and torsion springs is described on the 4th cylinder. The same procedure is applicable to cylinders 1 to 3.

Raise one end of torsion spring (1) with special tool 11 9 480.

Lift out intermediate lever (2) and set down in an orderly fashion.

IMPORTANT: Keep holding torsion spring (1) with special tool 11 9 480.

Fig 12: Raising One End Of Torsion Spring With Special Tool 11 9 480

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Attach special tool 11 9 490 to end of torsion spring.

Support end of torsion spring protected with special tool 11 9 490 on inlet camshaft.

Fig 13: Attaching Special Tool To End Of Torsion Spring

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IMPORTANT: Intermediate levers (2) are divided into individual tolerance classes. Only intermediate levers of the same tolerance class may be fitted in a single cylinder head. The tolerance classes are designated as illustrated with the numbers from 1 to 5. Used intermediate levers (2) may only be reused in the same position.

Fig 14: Identifying Intermediate Levers

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Raise second end of torsion spring (1) with special tool 11 9 480.

Lift out intermediate lever (2) and set down in an orderly fashion.

IMPORTANT: Keep holding torsion spring (1) with special tool 11 9 480.

Fig 15: Raising Second End Of Torsion Spring With Special Tool 11 9 480

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Attach special tool 11 9 490 to second end of torsion spring.

Support end of torsion spring protected with special tool 11 9 490 on inlet camshaft.

Fig 16: Attaching Special Tool To Second End Of Torsion Spring

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Release screw (1).

Fig 17: Releasing Torsion Spring Retaining Screw

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Remove torsion spring (1) and special tool 11 9 490.

Fig 18: Removing Torsion Spring And Special Tool

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Remove the intermediate levers and torsion springs of cylinders 1 to 3 according to the same procedure and set down in an orderly fashion.

Unscrew nut (special tool 11 9 473).

Fig 19: Identifying Knurled Nut

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IMPORTANT: Do not mix up the camshaft bearing covers of cylinders 1 to 4 and 5 to 8.

NOTE: Bearing caps are marked as illustrated with L E2 to L E5.

Remove bearing caps L E2 to L E5 and place to one side in order.

Fig 20: View Of Bearing Caps L E2 To L E5

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Lift out inlet camshaft (1).

Fig 21: View Of Inlet Camshaft

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NOTE: Further tasks:

The article removing and installing right eccentric shaft contains important installation instructions. Refer to 11 37 008 REMOVING AND INSTALLING/REPLACING RIGHT ECCENTRIC SHAFT (N62 TO 9/03) .

If necessary, replace plain compression rings (1).

IMPORTANT: Plain compression rings (1) can easily break.

Plain compression rings (1) are engaged at joint.

Press compression ring (1) on one side into groove, pull up on other side and remove catch.

Carefully pull compression ring (1) apart and remove towards front.

Fig 22: View Of Compression Ring

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NOTE: Inlet camshaft of cylinder bank 1 to 4 is marked with "EIN 14".

If necessary, replace sensor gear (1).

Release screw (2) and remove sensor gear (1).

Installation:

Installation of inlet camshaft is described separately from removal.

Clean all bearings and cams of inlet camshaft and lubricate with engine oil.

Fig 23: Locating Sensor Gear

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NOTE: Camshaft has a groove and sensor gear has a lug for fastening purposes.

Fig 24: Identifying Camshaft Groove And Sensor Gear Lug

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Fit sensor gear (1) and align to groove in camshaft.

Insert screw (2) and tighten down.

Tightening torque of screw, refer to (2) 11 31 14AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 25: Installing Sensor Gear In Groove In Camshaft

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Installing compression rings (1):

IMPORTANT: Plain compression rings (1) can easily break.

Carefully pull compression ring (1) apart and install from front.

Press compression ring (1) on one side into groove, install catch on other side.

Fig 26: View Of Compression Rings Into Groove

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Insert inlet camshaft (1) so that cams point upwards at 4th cylinder as shown in illustration.

Fig 27: Aligning 4th Cylinder Cam

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Make sure bearing shells (1) of eccentric shaft are engaged in bearing bracket.

NOTE: Bearing shell (1) is guided in a groove in bearing cap.

Fig 28: Identifying Bearing Shells

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Check dowel sleeves (1) for damage and correct installation position.

Fig 29: Locating Dowel Sleeves

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NOTE: Bearing caps are marked as illustrated with L E2 to L E5.

Fit bearing caps L E2 to L E5.

Fig 30: Identifying Bearing Caps

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NOTE: Initially tighten special tool 11 9 473 without play only.

Secure bearing bracket and bearing cap with nut (special tool 11 9 473).

Fig 31: Securing Bearing Bracket With Nut

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NOTE: The mounting of the bearing bracket described later can only be performed if the first bearing of the inlet camshaft is aligned with special tool 11 9 472.

Fit special tool 11 9 472 as shown in illustration and align inlet camshaft.

Fig 32: Aligning Inlet Camshaft

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Fit centering sleeves (special tool 11 9 475) and align special tool 11 9 472 to bearing caps 2 and 3.

Fig 33: Identifying Centering Sleeves

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Insert special tool 11 9 474 and initially tighten without play.

NOTE: Special tools 11 9 472 / 11 9 474 and 11 9 475 remain fitted until all torsion springs and intermediate levers have been installed.

Fig 34: View Of Guide Bushes

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NOTE: Installation of the intermediate levers and torsion springs is described on the 4th cylinder. The same procedure is applicable to cylinders 1 to 3.

Attach special tool 11 9 490 to ends of torsion spring.

Install torsion spring (1).

Fig 35: Installing Torsion Spring

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Insert screw (1) and tighten down.

Fig 36: Inserting Torsion Spring Screw

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IMPORTANT: Intermediate levers (2) are divided into individual tolerance classes. Only intermediate levers of the same tolerance class may be fitted in a single engine. The tolerance classes are designated as illustrated with the numbers from 1 to 5. Used intermediate levers (2) may only be reused in the same position.

Lubricate all sliding surfaces on intermediate lever (2) with engine oil.

Fig 37: Identifying Intermediate Levers

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Raise torsion spring (1) with special tool 11 9 480.

Detach special tool 11 9 490.

Fig 38: Raising Torsion Spring With Special Tool

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Hold torsion spring (1) with special tool 11 9 480.

Install intermediate lever (2) from above.

Insert end of torsion spring (1) into guide on intermediate lever (2).

Fig 39: Inserting End Of Torsion Spring Into Guide On Intermediate Lever

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Raise second end of torsion spring with special tool 11 9 480.

Detach special tool 11 9 490.

Fig 40: Raising Second End Of Torsion Spring With Special Tool

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Hold torsion spring (1) with special tool 11 9 480.

Install intermediate lever (2) from above.

Insert end of torsion spring (1) into guide on intermediate lever (2).

Fig 41: Inserting End Of Torsion Spring Into Guide On Intermediate Lever

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Install eccentric shaft sensor (2).

Insert screws and tighten down eccentric shaft sensor (2).

Fig 42: Locating Eccentric Shaft Sensor Retaining Screws

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Remove special tool 11 9 474.

Fig 43: Identifying Retaining Screws Of Support

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Remove special tool 11 9 472 and special tool 11 9 475.

Fig 44: View Of Guide Bushes

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Ends of compression rings (1) point upwards.

Make sure compression rings (1) are engaged at ends.

Fig 45: Identifying Ends Of Compression Rings

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IMPORTANT: Rocker arms (1) slip slightly when bearing bracket is fitted. Make sure rocker arms (1) are secured as illustrated on hydraulic valve clearance compensating elements and on valves.

Align rocker arms (1) straight.

Fig 46: View Of Rocker Arms

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Remove special tool 11 9 473.

Remove bearing bracket (1) from special tool 11 9 470.

Fig 47: Removing Bearing Bracket From Special Tool

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IMPORTANT: Do not tilt bearing bracket (1).

Lower bearing bracket (1) from above and carefully bring into contact with cylinder head.

Insert nuts and tighten by hand without play.

IMPORTANT: Make sure none of the intermediate levers or rocker arms have slipped out.

Tighten down nuts from inside to outside.

Tightening torque, refer to 11 31 1AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 48: Locating Bearing Bracket Nuts

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IMPORTANT: Do not mix up the camshaft bearing covers of cylinders 1 to 4 and 5 to 8.

Fit bearing cap L E1 in such a way that marking is legible from inlet side.

Install nuts and tighten down.

Tightening torque, refer to 11 31 1AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 49: View Of Bearing Cap L E1

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Rotate eccentric shaft at dihedral head as illustrated in order to reduce tension on torsion spring (1).

Pretension torsion spring (1) with a cable strap (2) and carefully fit on roller (3).

Fig 50: Securing Torsion Spring

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Rotate eccentric shaft at dihedral head as shown in illustration back to minimum stroke position.

Fig 51: Aligning Eccentric Shaft To Minimum Stroke Position

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Rotate inlet camshaft at hexagon head against direction of rotation until cam on 1st cylinder points downwards at an angle as shown in illustration.

Fig 52: Aligning Cam On 1st Cylinder

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Install inlet and exhaust adjustment unit on right side. Refer to 11 36 048 REMOVING AND INSTALLING/REPLACING INLET AND EXHAUST ADJUSTMENT UNITS ON RIGHT SIDE (N62/N62TU) .

Install spark plugs on cylinder bank 1 to 4.

Install right cylinder head cover. Refer to 11 12 006 REMOVING AND INSTALLING/SEALING RIGHT CYLINDER HEAD COVER (N62/N62TU) .

Install ignition coils on cylinder bank 1 to 4.

Install servomotor for right eccentric shaft. Refer to 11 37 024 REMOVING AND INSTALLING/REPLACING SERVOMOTOR FOR RIGHT ECCENTRIC SHAFT (N62/N62TU) .

Assemble engine.