11 31 019 Replacing camshafts (S54): Installation:

WARNING: This page is about a different car, the 2002 BMW M Roadster, 2002 BMW M Coupe, 2001 BMW M Roadster, and 2001 BMW M Coupe. However, it is still accessible from the selected car via links, so may be relevant.

Installation of camshafts and the VANOS adjustment unit is described separately from removal. The assembly sequence for removal and installation is different.

CAUTION: Danger of mixing up

The inlet camshaft has an identifying groove behind the locating bore.

(A) Exhaust camshaft without groove

(E) Inlet camshaft with groove

Fig 1: Identifying Camshafts

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Signal rings of inlet and exhaust camshafts are different.

(A) Signal disk of exhaust camshaft with seven blades.

(E) Signal disk of inlet camshaft with six blades.

Fig 2: Identifying Signal Rings Of Camshafts

Courtesy of BMW OF NORTH AMERICA, INC.

Fit signal disks, align locating lug to groove.

Install banjo bolt (1) and tighten down.

Fig 3: Installing Banjo Bolt

Courtesy of BMW OF NORTH AMERICA, INC.

Tightening torque, 11 31 13AZ. Refer to 11 31 CAMSHAFT .

NOTE: Clean dirty parts.

Oil following parts before installation:

Contact faces of camshafts in cylinder head
Rocker arm
Cams and contact faces of camshafts
Bearing cover

Installing inlet camshaft:

Install inlet camshaft in such a way that cams on cylinder 1 point horizontally inwards.

Fig 4: Installing Inlet Camshaft

Courtesy of BMW OF NORTH AMERICA, INC.

Inlet side:

CAUTION: Incorrect removal/installation without a special tool exposes the camshaft to the risk of preliminary damage or breakage.

Fit special tool 11 4 380 on inlet camshaft and screw into spark plug threads of cylinders 2 and 5.

Fig 5: Fitting Special Tool On Inlet Camshaft

Courtesy of BMW OF NORTH AMERICA, INC.

Inlet side:

Pretension inlet camshaft by rotating eccentric shaft.

Fig 6: Rotating Eccentric Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Inlet side:

CAUTION: Risk of mixing up parts.
Fit inlet side bearing caps so that lug (2) points outwards to inlet side.

Fig 7: Fitting Inlet Side Bearing Caps

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Bearing caps are secured with adapter sleeves (1).

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

Inlet side:

NOTE: Bearing caps are marked E2 to E7.

Install bearing caps E2 to E7.

Fig 8: Identifying Bearing Caps

Courtesy of BMW OF NORTH AMERICA, INC.

Inlet side:

Align bearing caps by hand until they are secured by means of adapter sleeves.

Insert all nuts of bearing caps on inlet camshaft.

Manually tighten bearing cap nuts and then tighten down from inside to outside in 1/2 turn increments.

Tightening torque, 11 31 1AZ. Refer to 11 31 CAMSHAFT .

Remove special tool 11 4 380.

Fig 9: Removing Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Inlet side:

CAUTION: Note direction and angle of rotation.

Rotate inlet camshaft at hexagon from horizontal position upwards until locating bore (1) in camshaft is vertical.

Fig 10: Rotating Inlet Camshaft

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Pay attention to installation direction of special tool 11 9 130.

(A) Exhaust side

(E) Inlet side

Fig 11: Identifying Installation Direction Of Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Inlet side:

Attach special tool 11 9 130 to cylinder head.

Fig 12: Aligning Inlet Camshaft

Courtesy of BMW OF NORTH AMERICA, INC.

Align inlet camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Special tool 11 9 130 must rest flat on cylinder head.

Remove special tool 11 9 130 and special tool 11 7 342.

Installing exhaust camshaft:

Clean dirty parts.

Oil following parts before installation:

Contact faces of camshafts in cylinder head
Rocker arm
Cams and contact faces of camshafts
Bearing cover

Install exhaust camshaft in such a way that cams on cylinder 1 point horizontally inwards.

Fig 13: Installing Exhaust Camshaft

Courtesy of BMW OF NORTH AMERICA, INC.

Exhaust side:

CAUTION: Incorrect removal/installation without a special tool exposes the camshaft to the risk of preliminary damage or breakage.

Fit special tool 11 4 380 on exhaust camshaft and screw into spark plug threads of cylinders 2 and 5.

Fig 14: Fitting Special Tool On Exhaust Camshaft

Courtesy of BMW OF NORTH AMERICA, INC.

Exhaust side:

Pretension exhaust camshaft by rotating eccentric shaft.

Fig 15: Rotating Eccentric Shaft

Courtesy of BMW OF NORTH AMERICA, INC.

Exhaust side:

CAUTION: Risk of mixing up parts.
Fit exhaust side bearing caps so that lug (2) points outwards to exhaust side.

NOTE: Bearing caps are secured with adapter sleeves (1).

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

Fig 16: View Of Exhaust Side Bearing Cap

Courtesy of BMW OF NORTH AMERICA, INC.

Exhaust side:

NOTE: Bearing caps are marked A2 to A7.

Install bearing caps A2 to A7.

Fig 17: Installing Bearing Caps

Courtesy of BMW OF NORTH AMERICA, INC.

Exhaust side:

Align bearing caps by hand until they are secured by means of adapter sleeves.

Insert all nuts of bearing caps on exhaust camshaft.

Manually tighten bearing cap nuts and then tighten down from inside to outside in 1/2 turn increments.

Tightening torque, 11 31 1AZ. Refer to 11 31 CAMSHAFT .

Remove special tool 11 4 380.

Fig 18: Removing Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Exhaust side:

CAUTION: Note direction and angle of rotation.

Rotate exhaust camshaft at hexagon from horizontal position upwards until locating bore (1) in camshaft is vertical.

Fig 19: Rotating Exhaust Camshaft

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Pay attention to installation direction of special tool 11 9 130.

(A) Exhaust side

(E) Inlet side

Fig 20: Identifying Installing Direction Of Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Exhaust side:

Attach special tool 11 9 130 to cylinder head.

Fig 21: Aligning Exhaust Camshaft

Courtesy of BMW OF NORTH AMERICA, INC.

Align exhaust camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Special tool 11 9 130 must rest flat on cylinder head.

Remove special tool 11 9 130 and special tool 11 7 342.

NOTE: Inlet and exhaust camshafts have a joint thrust bearing flange (1) at 1st bearing seat.

Check adapter sleeves (2) for damage and correct installation position.

Fig 22: Fitting Thrust Bearing Flange

Courtesy of BMW OF NORTH AMERICA, INC.

Observing installation direction:

Fit thrust bearing flange (1) as shown in illustration.

Align thrust bearing flange (1) by hand until it is secured to cylinder head by means of adapter sleeves.

Install nuts of thrust bearing flange (1).

Manually tighten nuts and then tighten down in 1/2 turn increments.

Fig 23: Installing Thrust Bearing Flange

Courtesy of BMW OF NORTH AMERICA, INC.

Coat toothing of toothed sleeves (3) with engine oil as antiseize agent.

Install toothed sleeves (3) of exhaust and inlet camshafts.

Align bores in toothed sleeves (3) to tapped holes in camshafts.

Fig 24: Installing Toothed Sleeves Of Camshafts

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Note installation direction of thrust washers (2).

Large chamfer points to camshaft.

Fig 25: Identifying Installation Direction Of Thrust Washers

Courtesy of BMW OF NORTH AMERICA, INC.

Note installation direction of thrust washers (2).

Fit thrust washers (2) on centering sleeves (1) in such a way that large chamfer points towards rear to camshaft.

Fig 26: Fitting Thrust Washers On Centering Sleeves

Courtesy of BMW OF NORTH AMERICA, INC.

Fit centering sleeve (1) on exhaust and inlet sides with thrust washer (2).

Fig 27: Fitting Centering Sleeves

Courtesy of BMW OF NORTH AMERICA, INC.

Grip camshafts at hexagon head.

Tighten down bolts on centering sleeves (1).

Inlet side:

CAUTION: Pay attention to installation direction of special tool 11 9 130.

Attach special tool 11 9 130 to cylinder head. Align inlet camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Fig 28: Attaching Special Tool To Cylinder Head

Courtesy of BMW OF NORTH AMERICA, INC.

Special tool 11 9 130 must rest flat on cylinder head. Remove special tool 11 7 342.

Exhaust side:

Align exhaust camshaft at hexagon until special tool 11 7 342 can be joined by means of special tool 11 9 130 in locating bore.

Fig 29: Aligning Exhaust Camshaft

Courtesy of BMW OF NORTH AMERICA, INC.

Special tool 11 9 130 must rest flat on cylinder head.

Remove special tool 11 9 130 and special tool 11 7 342.

Lift timing chain and hold under tension.

Rotate crankshaft from 30° before TDC position in direction of rotation as far as firing TDC position. Secure vibration damper in position with special tool 11 2 300.

Fig 30: Securing Vibration Damper In Position

Courtesy of BMW OF NORTH AMERICA, INC.

Hold timing chain under tension.

Position tapped holes of thrust washer horizontally as shown in illustration.

Fig 31: Identifying Position Of Tapped Holes

Courtesy of BMW OF NORTH AMERICA, INC.

Install sprocket wheel (2) on inlet side on centering sleeves in such a way that elongated holes are centrally located.

Fig 32: Installing Sprocket Wheel

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The position of the elongated holes is only important in terms of accessibility to the screws and does not affect operation in any way.

Hold timing chain under tension and feed on sprocket wheel (1).

Install sprocket wheel (1) on exhaust side on centering sleeves in such a way that elongated holes of sprocket wheels (1 and 2) are centrally located.

Press tensioning rail against timing chain and check position of elongated holes.

NOTE: The position of the elongated holes is only important in terms of accessibility to the screws and does not affect operation in any way.

Install chain tensioning piston. Refer to 11 31 090 Removing and installing/replacing chain tensioning piston (S54) .

NOTE: Coat all sliding surfaces on VANOS gear with engine oil as antiseize agent.

Exhaust side:

NOTE: The small support diameter of the plate spring (2) points in the direction of the supporting ring (3). Supporting ring is supported with retaining lugs in spline hub (1).

Insert plate spring (2) and supporting ring (3) in spline hub (1).

Fig 33: Inserting Plate Spring And Supporting Ring In Spline Hub

Courtesy of BMW OF NORTH AMERICA, INC.

Exhaust side:

Take care: the supporting ring can easily fall out.

Remove spline hub with plate spring and supporting ring.

Bore hole (1) must point upwards as shown in illustration.

Fig 34: Identifying Bore Hole

Courtesy of BMW OF NORTH AMERICA, INC.

Exhaust side:

Insert all screws of spline hub (1) and tighten by hand until free of play.

Then slacken screws again until spline hub (1) can be moved with fingers.

Fig 35: Inserting Screws Of Spline Hub

Courtesy of BMW OF NORTH AMERICA, INC.

Inlet side:

NOTE: The small support diameter of the plate spring (2) points in the direction of the supporting ring (3). Supporting ring is supported with retaining lugs in spline hub (1).

Insert plate spring (2) and supporting ring (3) in spline hub (1).

Fig 36: Inserting Plate Spring And Supporting Ring

Courtesy of BMW OF NORTH AMERICA, INC.

Inlet side:

Take care: the supporting ring can easily fall out.

Remove spline hub with plate spring and supporting ring.

Bore hole (1) must point upwards as shown in illustration.

Fig 37: Identifying Bore Hole

Courtesy of BMW OF NORTH AMERICA, INC.

Inlet side:

Insert all screws of spline hub (1) and tighten by hand until free of play.

Then slacken screws again until spline hub (1) can be moved with fingers.

Fig 38: Inserting Screws Of Spline Hub

Courtesy of BMW OF NORTH AMERICA, INC.

Detach control valve (1) from VANOS adjustment unit.

Fig 39: Detaching Control Valve From VANOS Adjustment Unit

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: A filter is integrated in the control valve.

The control valve must be replaced after any damage which suggests that the filter is fouled with filings/shavings.

Replace sealing rings (1) and coat with oil as antiseize agent.

Fig 40: Locating Sealing Rings

Courtesy of BMW OF NORTH AMERICA, INC.

Preassemble control valve in cylinder head.

Oil is sprayed when splined shafts are pressed back. Cover bore (1) with a cloth.

Fig 41: Connecting Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

Connect special tool 12 6 050 in conjunction with special tool 12 6 411 (from special tool kit 12 6 410) to solenoid valves of VANOS adjustment unit.

Connect special tool 12 6 411 to correct terminals on car battery. Press buttons 1 and 3 on special tool 12 6 050 simultaneously. Solenoid valves are actuated.

Press splined shafts by hand up to stop into initial position.

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

Fig 42: Checking Dowel Sleeves

Courtesy of BMW OF NORTH AMERICA, INC.

Replace gasket (1).

Fig 43: Replacing Gasket

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Note direction of installation of gasket.
Install gasket (1) in such a way that beading points to VANOS adjustment unit.
Secure gasket (1) with sealing compound on adapter sleeves.

Secure special tool 11 9 170 as shown in illustration by means of stud bolt.

Fig 44: Securing Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The special tool 11 9 170 serves to maintain a prespecified distance during the below-mentioned installation of the VANOS adjustment unit.

Turn spline hubs (1) of inlet and exhaust camshafts to right limit position.

Fig 45: Turning Spline Hubs Of Camshafts

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Special tool 11 9 170 remains as a spacer element between cylinder head and VANOS adjustment unit.

Attach VANOS adjustment unit.

Fig 46: Attaching VANOS Adjustment Unit

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Make sure both VANOS splined shafts remain in initial position during installation.

Rotate splined shafts of inlet and exhaust sides until spur toothing is engaged.

Push VANOS adjustment unit with splined shaft into VANOS gear until helical cut splines (2) are positioned shortly before meshing with spline hub (1).

Fig 47: Pushing VANOS Adjustment Unit Into Vanos Gear

Courtesy of BMW OF NORTH AMERICA, INC.

Exhaust side:

If the helical cut splines cannot be pushed into the spline hub(1):

Place special tool 11 7 160 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".

Fig 48: Placing Special Tool On Bore In Spline Hub (Exhaust)

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: The "first" matching tooth must engage.

Inlet side:

Place special tool 11 7 160 on bore in spline hub (1). Rotate spline hub (1) against direction of rotation until splined shaft (2) is positioned with spline hub (1) exactly "tooth-to-tooth gap".

Fig 49: Placing Special Tool On Bore In Spline Hub (Inlet)

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: The "first" matching tooth must engage.

Exhaust side:

Align radial piston pump to driver on spline hub.

NOTE: Picture shows a schematic representation.

Fig 50: Aligning Radial Piston Pump To Driver On Spline Hub

Courtesy of BMW OF NORTH AMERICA, INC.

Push on VANOS adjustment unit until it contacts special tool 11 9 170.

CAUTION: If this position is not reached, realign position of radial piston pump to driver.

Fig 51: Pushing On VANOS Adjustment Unit

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Do not tighten down screws.

NOTE: Screw on left and right serves to secure the VANOS adjustment unit.

Insert a screw on left and right and tighten by hand until free of play.

Fig 52: Securing VANOS Adjustment Unit

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The procedure described below helps to provide compensation for play.
Only with this compensation for play is the timing diagram correctly set.

NOTE: To tighten down screws on VANOS gear: Use special tool 117 200.

Tighten down the two opposing screws on the inlet and exhaust sides of the VANOS gear to 10 Nm.

Then slacken all four screws by a 1/4 turn.

Fig 53: Tightening Down Screws On VANOS Gear

Courtesy of BMW OF NORTH AMERICA, INC.

Remove special tool 11 9 170 on left and right sides.

Fig 54: Removing Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Make sure that radial piston pump is aligned to driver on spline hub.
When the left and right screws are tightened down alternately, the exhaust and inlet camshafts must not rotate.
If the camshafts do rotate, this means that the screws on the VANOS gear were not previously released correctly.

Fig 55: Aligning Piston Pump To Driver On Spline Hub

Courtesy of BMW OF NORTH AMERICA, INC.

Alternately tighten down bolts in 1/2 turn increments carefully and evenly until VANOS adjustment unit rests against timing case cover.

Insert remaining screws and tighten down.

Fig 56: Inserting Remaining Screws

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Use special tool 11 7 200 to tighten down bolts on VANOS gear.

Fig 57: Tightening Down Bolts On VANOS Gear

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten down six accessible screws (three on exhaust side and three on inlet side) on VANOS gear to 10 Nm.

Fig 58: Tightening Down Accessible Screws On VANOS Gear

Courtesy of BMW OF NORTH AMERICA, INC.

Remove special tool 11 2 300. Rotate crankshaft in direction of rotation a further revolution up to overlap TDC position.

NOTE: TDC allocation above marking on vibration damper is sufficient.

Fig 59: Rotating Crankshaft

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Use special tool 11 7 200 to tighten down bolts on VANOS gear.

Fig 60: Tightening Down Bolts On VANOS Gear

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten down remaining six screws (three on exhaust side and there on inlet side) on VANOS gear 10 Nm.

Fig 61: Tightening Down Remaining Screws On VANOS Gear

Courtesy of BMW OF NORTH AMERICA, INC.

Then crank engine again in direction of rotation until 1st cylinder is at TDC firing position.

Secure vibration damper in position with special tool 11 2 300.

Fig 62: Securing Vibration Damper

Courtesy of BMW OF NORTH AMERICA, INC.

Check camshaft setting:

Attach special tool 11 9 140 and join in inlet camshaft.

NOTE: The inlet camshaft is correctly adjusted when special tool 11 9 140 rests flat on the cylinder head or protrudes by max. 0.5 mm to the exhaust side.

If the special tool 11 9 140 protrudes to the inlet side, the timing must be readjusted.

Fig 63: Checking Inlet Camshaft Setting

Courtesy of BMW OF NORTH AMERICA, INC.

Join special tool 11 9 140 in exhaust camshaft.

Fig 64: Checking Exhaust Camshaft Setting

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The exhaust camshaft is correctly adjusted when special tool 11 9 140 rests flat on the cylinder head or protrudes by max. 0.5 mm to the exhaust side.

If the special tool 11 9 140 protrudes to the inlet side, the timing must be readjusted.

If necessary, adjust camshaft timing. Refer to 11 31 005 Checking camshaft timing (S54) .

NOTE: Check installed direction.

Install holder (4)

Fig 65: Installing Holder

Courtesy of BMW OF NORTH AMERICA, INC.

Insert screws (3) and secure holder (4) (do not tighten down screws (3) yet)
Install sliding rail (2).
Insert screws (1).
Tighten down screws (1) and screws (3).

Fig 66: Installing Sliding Rail
Courtesy of BMW OF NORTH AMERICA, INC.

Replace sealing rings of banjo bolt.

Insert banjo bolt but do not tighten down yet.

Fig 67: Inserting Banjo Bolt

Courtesy of BMW OF NORTH AMERICA, INC.

Install bracket of oil line. Install screw and tighten down.

Fig 68: Installing Bracket Of Oil Line

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten down banjo bolt of oil line.

Tightening torque, 11 36 9AZ. Refer to 11 36 VARIABLE CAMSHAFT CONTROL .

Fig 69: Tightening Down Banjo Bolt Of Oil Line

Courtesy of BMW OF NORTH AMERICA, INC.

Remove special tool 11 2 300.

Fig 70: Removing Special Tool From Vibration Damper

Courtesy of BMW OF NORTH AMERICA, INC.

Adjust valves. Refer to 11 34 004 Adjusting valve clearance (S54) .

Assemble engine.

CAUTION: There is air in the VANOS system once it is opened.
In the first few seconds after startup this results in a clearly discernible "rattling noise".
This rattling noise does "not" indicate incorrect assembly.
The rattling noise will disappear as soon as the oil pressure has built up and the system has vented.