Assembling the cylinder head

Install all valves

NOTE: RISK OF DAMAGE
Contaminant or foreign body.
Contamination can result in malfunctions, loss of function or leaks.

Adhere to the utmost cleanliness.
Protect components from contamination e.g. by covering.
Close off line connections with seal plugs.

Slide the valve (1) carefully in the cylinder head.

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B38:
Prepare the special tools 0 494 371 (11 9 006) , 0 494 372 (11 9 007) and 0 494 373 (11 9 008) as shown.

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B46B48:
Prepare the special tools 0 494 371 (11 9 006) , 0 494 372 (11 9 007) and 0 494 373 (11 9 008) as shown.

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B58:
Prepare plastic shaped parts (1) with the shaped parts (2) and aluminum frame insert (3) .

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B38:
Prepare the special tools 0 494 373 (11 9 008) for the corresponding alignment in the next step.

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Version B46/B48:
0 494 373 (11 9 008) for the corresponding alignment in the next step is to be prepared.

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NOTE: TECHNICAL INFORMATION
The figure shows the engine B58.
Position the special tools 0 494 371 (11 9 006) , 0 494 372 (11 9 007) and 0 494 373 (11 9 008) on the cylinder head in the center in arrow direction.

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Turn round special tool 0 494 371 (11 9 006) and insert as shown.
Lock the special tools 0 494 370 (11 9 005) in arrow direction.

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Shift the special tools 0 494 370 (11 9 005) in arrow direction via the edges of the special tools 0 494 371 (11 9 006) and lock them.

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Turn the special tool 0 494 366 (11 9 001) (2) on the crank (1) by 180° in arrow direction.

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Installing valve stem seals

NOTE: RISK OF DAMAGE
Contaminant or foreign body.
Contamination can result in malfunctions, loss of function or leaks.

Adhere to the utmost cleanliness.
Protect components from contamination e.g. by covering.
Close off line connections with seal plugs.

NOTE: The description is provided only at one component. The procedure is the same for all other components.

Remove oil and dirt from the contact surface (1) .

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NOTE: TECHNICAL INFORMATION

As an alternative to special tool 0 490 797 (11 1 960) , the assembly sleeves delivered with the spare part can be used (see applicable BMW parts catalogue).
Make sure that the special tool 0 490 797 (11 1 960) or the assembly sleeves are used when installing the valve stem seal.
Guide in and install special tool 0 490 797 (11 1 960) or assembly sleeves on valve (1).

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Replace the valve stem seal (1) or assembly sleeves.
Parts: Valve stem seal, assembly sleeves
Guide in and install valve stem seal (1) on special tool 0 490 797 (11 1 960) or assembly sleeves.

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Guide out and remove special tool 0 490 797 (11 1 960) or assembly sleeves.

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Prepare special tool 0 493 249 (11 6 380) .

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Press the valve stem seal (1) onto the cylinder head 0 493 249 (11 6 380) up to the stop using special tool.

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Make sure that the valve stem seal (1) is correctly positioned on cylinder head (2) .

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Install all valve springs

Note the installation position of the valve spring.

NOTE: Install the valve spring so that the larger diameter (Y) points to the bottom spring cup.

Make sure that the intake valves are not switched with the exhaust valves.

NOTE: Valve springs (1) are marked in color (2). Color for the intake valves: Green

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Note the installation position of the valve spring.
NOTE: Install the valve spring so that the larger diameter (Y) points to the bottom spring cup.
Make sure that the intake valves are not switched with the exhaust valves.

NOTE: Valve springs (1) are marked in color (2). Color for the exhaust valves: green/yellow

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Install the valve spring (2) and spring cup (1) .

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CAUTION: Component with preload.
Injury hazard!

Reduce preload as far as possible before disassembly. Relieve component.

Align special tool in direction of valve axis.

Select the corresponding groove using special tool 0 495 028 (11 9 017) .
Press down the valve spring on the upper spring cup with the special tools 0 494 374 (11 9 009) and 0 495 028 (11 9 017) .
Hold the valve spring in the pressed down position using special tool 0 494 375 (11 9 011) .

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Keep the valve spring pressed down with the special tool 0 495 028 (11 9 017) .
Install the valve shims (1) of the valve (2) with a magnet.
Relieve load on valve spring.

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Unlock special tool 0 494 370 (11 9 005) in the arrow direction and remove.

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Installing all hydraulic valve clearance compensating elements

NOTE: TECHNICAL INFORMATION
If the hydraulic valve clearance compensating elements are reused, they must be reinstalled at the same position.

Install all the hydraulic valve clearance compensating elements (1) in the direction of arrow.

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Install all roller cam followers

Observe the classification of roller cam followers.

The classification in digits from 1 to 5 has been printed on the roller cam follower.

Classification	Idle speed
1	Repair case - slow engine speed when idling
2	Installed as standard/Initial installation
3	Installed as standard/Initial installation
4	Installed as standard/Initial installation
5	Repair case - high engine speed when idling

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Install the roller cam follower (1) on the intake side.
Make sure that the roller cam follower (1) is correctly positioned on the hydraulic valve clearance compensating element (arrows) and the intake valves.

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Install the roller cam follower (1) on the exhaust side.
Make sure that the roller cam follower (1) is positioned correctly on the hydraulic valve clearance compensating elements (arrows) and the exhaust valves.

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Install exhaust camshaft

Check fitting sleeves (1) to ensure that they fit correctly and check for damage; if necessary, replace them.

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Coat all bearing positions (1) with fresh motor oil.

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Clean all bearing positions of the exhaust camshaft bearing caps (A1) , (A2) , and (A) and coat with fresh motor oil.
Clean the bearing positions (1) of the high pressure pump bracket and coat with fresh motor oil.

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Clean all the bearing positions (arrows) of the exhaust camshaft (1) and coat with fresh motor oil.

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Make sure that the roller cam follower (1) is fitted correctly before installing the exhaust camshaft.
Coat exhaust camshaft and exhaust camshaft bearing cap with fresh motor oil.

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Insert exhaust camshaft in the cylinder head, such that the mark (1) points upwards.

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NOTE: TECHNICAL INFORMATION
The camshaft bearing caps must not be mixed up. The camshaft bearing caps must be installed in the installation position from which they were removed.

Position exhaust camshaft bearing caps (A1) , (A2) and (A) on the cylinder head.

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NOTE: The exhaust camshaft bearing caps are legibly labeled from the intake side and marked with A1, A2 and A.

NOTE: Exhaust camshaft bearing cap A is a thrust bearing.

Check the tensile strength of the screws for the bearing caps.
The illustration shows the screws with a tensile strength of 8.8.

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Check the tensile strength of the screws for the bearing caps.

The illustration shows the screws with a tensile strength of 10.9.

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NOTE: TECHNICAL INFORMATION
The camshaft is under tension due to the valve springs. Tighten or loosen each screw on the camshaft bearing caps in the prescribed sequence only by half a turn. Repeat procedure.

Coat both bearing positions at the high-pressure pump bracket with fresh motor oil.
Position the high pressure pump bracket on the cylinder head.

Fig 1: Exhaust Camshaft Bearing Caps Bolts Tightening Sequence
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Join all bolts of the exhaust camshaft bearing caps in sequence (1) to (10) in half turns.
Observe the joining torque.
Tighten all bolts of the exhaust camshaft bearing caps in sequence (1) to (10) .

TIGHTENING TORQUE SPECIFICATIONS

Exhaust camshaft to cylinder head
M6	Tensile strength of screw 8.8 Joining torque	9.6 Nm
M6	tightening torque	9.6 Nm
M6	Tensile strength of screw 10.9 Joining torque	11.8 Nm
M6	tightening torque	11.8 Nm

Position and install the roller tappet (1) .
Make sure the pin (2) is correctly positioned in the guide (3) .
Insert and install the roller tappet (1) .

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Install eccentric shaft

Check the guide sleeves (1) for damage, replace if necessary.

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Check needle bearing (1) for ease of movement.

NOTE: In the event of tight needle bearings, replace eccentric shaft (2).

Coat the needle bearing (1) with new motor oil.

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Clean the bearing positions (1) and coat with new motor oil.

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Clean all the bearing positions (1) of the bearing brackets and coat with fresh motor oil.
Clean the bearing position (2) of the bearing cap and coat with new motor oil.

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Before installing the eccentric shaft, push needle bearing (1) in arrow direction up to the stop.

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Insert eccentric shaft (1) in the cylinder head.
Attach bearing cap (2) and bearing brackets (3) on the cylinder head.
For an engine that has been in use, make sure all bearing brackets are reinstalled in the same position.

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Make sure the bearing cap (1) is installed correctly.

NOTE: Bearing cap (1) is provided with a stop.

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Tighten down screws (1) and (2) uniformly.

TIGHTENING TORQUE SPECIFICATIONS

Eccentric shaft to bearing bracket/cylinder head
M6	Tightening torque	10 Nm

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Installing the servomotor for the eccentric shaft (cylinder head removed)

Replace seal (1) .

Parts: Gasket

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Press the seal (1) up to the limit position on the housing.

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Grease the gearing (1) of the servomotor (2) for the eccentric shaft in marked area.

Consumable

Lubricating grease Longtime PD-1

400 g, Cartridge

83192160340

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Clean sealing surface (1) .

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Feed in and install the servomotor (1) for the eccentric shaft up to the stop.
Turn the servomotor (1) for the eccentric shaft with a commercially available Allen wrench (2) with 4 mm in arrow direction until the servomotor (1) lies on the cylinder head for the cylinder head.
Tighten down screws (3) .

TIGHTENING TORQUE SPECIFICATIONS

Electrical servomotor to cylinder head
M6	tightening torque	8 Nm

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Install intake camshaft

Check the fitting sleeves for correct fit and damage and replace if necessary.

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Coat all bearing positions (1) with fresh motor oil.

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Clean all bearing positions of the intake camshaft bearing cap (E1) , (E2) , (E3) , (E4) and (E) and coat with motor oil.

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Clean all the bearing positions (arrows) of the intake camshaft (1) and coat with motor oil.

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Before installing the intake camshaft, check the correct seat of the roller cam follower (1) .
Coat the roller cam follower (1) with fresh motor oil.

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Insert the intake camshaft into the cylinder head in such a way that the mark (1) points up.

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NOTE: TECHNICAL INFORMATION
The camshaft bearing caps must not be mixed up. The camshaft bearing caps must be installed in the installation position from which they were removed.

Position the intake camshaft bearing cap (E1) , (E2) , (E3) , (E4) and (E) on the cylinder head.

NOTE: The intake camshaft bearing caps are legibly labeled from the intake side with E1, E2, E3, E4 and E.

NOTE: Intake camshaft bearing cap E is a thrust bearing.

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Check the tensile strength of the screws for the bearing caps.
The illustration shows the screws with a tensile strength of 8.8.

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Check the tensile strength of the screws for the bearing caps.
The illustration shows the screws with a tensile strength of 10.9.

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Press down the intake camshaft bearing cap and hand-tighten screws in the sequence (1) to (10) step-wise.
Join the screws in sequence (1) to (10) in half turns.
Observe the joining torque.
Tighten all screws in the sequence from (1) to (10) .

Fig 2: Intake Camshaft Bearing Caps Screws Tightening Sequence

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TIGHTENING TORQUE SPECIFICATIONS

Intake camshaft to cylinder head
M6	Tensile strength of screw 8.8 Joining torque	9.6 Nm
M6	tightening torque	9.6 Nm
M6	Tensile strength of screw 10.9 Joining torque	11.8 Nm
M6	tightening torque	11.8 Nm

Checking installation position of roller cam followers

NOTE: TECHNICAL INFORMATION
The rocker arms may slip slightly when the camshaft is positioned. Make sure rocker arms are correctly positioned on the hydraulic valve clearance compensating elements and on valves.

Make sure the installation position (arrows) of the roller cam followers (1) is correct.

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Checking the intermediate lever classification

NOTE: TECHNICAL INFORMATION
All intermediate levers are classified. Only one classification may be used per engine.
All intermediate levers must be reinstalled in the same positions in an engine which has already been in use.

Check the classification (arrow) of the intermediate lever.

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Installing all intermediate levers

NOTE: TECHNICAL INFORMATION
When replacing one or more intermediate levers:
When removing the intermediate lever, it is imperative to note the part number of the intermediate lever.
A mixed installation of intermediate levers is only permitted in combination with the appropriate torsion spring.
For further information on possible combinations, see the applicable BMW parts catalogue.

Version with torsion spring with L-shaped contour and appropriate intermediate lever:
Use the torsion spring (1) with L-shaped contour only in connection with the appropriate intermediate lever (2) .

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Version with torsion spring with S-shaped contour and appropriate intermediate lever:
Use the torsion spring (1) with S-shaped contour only in connection with the appropriate intermediate lever (2) .

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NOTE: The description is provided only at one component. The procedure is the same for all other components.

Install the intermediate lever (1) .

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Installing all gates

Have the special tool 2 359 089 ready.

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Clean contact surfaces (1) and (2) and remove the oil, grease and dirt.

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Position the gate (2) and hand-tighten the screw (1) .
Make sure the intermediate lever (3) is in the correct installation position.

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Position the special tool 2 359 089 on the cylinder head.
Pre-tension the gate with the lever (3) . Abut the screw (1) in the area (2) .
Make sure that the special tool 2 359 089 does not rotate during this process.

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Secure the gate with the lever (1) in the direction of the arrow.

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Make sure that the special tool 2 359 089 rests flat against the cylinder head (arrows).

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Press the special tool onto the cylinder head 2 359 089 in arrow direction and tighten the screw (1) simultaneously.

TIGHTENING TORQUE SPECIFICATIONS

Gate to bearing bracket
M7x35	Tightening torque	23 Nm

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Check the conventional gauge (1) in the area (A) for the correct gap dimension.

TECHNICAL DATA SPECIFICATION

Gap dimension between gate and bearing bracket
	Gap dimension A	0.03 mm

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Make sure the gate (1) lies correctly against the bearing bracket (2) .
The gate (1) is correctly installed in the marked area.

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Make sure that the gate lies (1) correctly on the bearing bracket (2) .
The gate (1) is not correctly installed in the marked area.

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Repeat the step for all the gates.

Checking the position of the intake camshaft (cylinder head removed)

Check

Check position of the intake camshaft on the respective cylinders.

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Result

» Cam (1) of the intake camshaft runs on the intermediate lever.

Measure

Continue to crank the intake camshaft on the mounting flats.

Installing torsion springs

CAUTION: Spring preload.
Injury hazard!

The use of the specified special tool (tool) is mandatory.
Carry out the described steps properly.

NOTE: TECHNICAL INFORMATION
Wear safety goggles.

NOTE: TECHNICAL INFORMATION
For disassembly and installation of the torsion spring, special tool 2 359 088 is used. Due to technical modifications in the torsion spring, special tool 5 A0B 120 is mounted on the existing special tool 2 359 088 .
Information on modification can be found in the additional information.

NOTE: TECHNICAL INFORMATION
Alternative to the new special tool 5 A24 F30 , the already known special tool SWZ: 2 359 088 can be used in modified form.
Information on modification can be found in the additional information.
The modified special tool is upward compatible.

NOTE: TECHNICAL INFORMATION
When replacing one or more torsion springs:
When removing the torsion spring, it is imperative to note the part number of the torsion spring.
A mixed installation of torsion springs is only permitted in combination with the appropriate intermediate lever.
For further information on possible combinations, see the applicable BMW parts catalogue.

Version with a torsion spring with an L-shaped contour and a suitable intermediate lever:
Use torsion spring (1) with an L-shaped contour only in conjunction with a suitable intermediate lever (2) .

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Version with a torsion spring with an S-shaped contour and a suitable intermediate lever:
Use torsion spring (1) with an S-shaped contour only in conjunction with a suitable intermediate lever (2) .

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Keep set of special tools 2 359 088 for removing the torsion spring with an S-shaped contour ready:

Number	Description
1	Clamping lever
2	Mount for the clamping lever (torsion spring with an S-shaped contour)

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Keep set of special tools 5 A24 F30 or, alternatively, the modified special tool 2 359 088 for removing the torsion spring with an L/S-shaped contour ready:

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Number	Description
1	Clamping lever
2	Mount for the clamping lever (torsion spring with an L/S-shaped contour)

Version with a torsion spring with an S-shaped contour with special tool 5 A24 F30 or the modified special tool 2 359 088 :
Move shaped part (1) to the contact surface in the arrow direction.

Turn wing screw (2) until hand-tight.

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Version with a torsion spring with an L-shaped contour with special tool 5 A24 F30 or the modified special tool 2 359 088 :
Move shaped part (1) to the contact surface in the arrow direction.

Turn wing screw (2) until hand-tight.

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Position torsion spring (1) in clamping lever (2) .
Torsion spring (1) must be positioned correctly in the marked area (3) of clamping lever (2) .

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Version with a torsion spring with an S-shaped contour with special tool 2 359 088 :
Close clamping lever (1) of special tool 2 359 088 carefully in the corresponding mount until the snap-in hooks engage audibly.

Ensure that torsion spring (2) lies correctly in the lateral guides (arrows) and mark of clamping lever (1) when tensioning.

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Version with a torsion spring with an S-shaped contour with special tool 5 A24 F30 or the modified special tool 2 359 088 :
Close clamping lever (1) of special tool 5 A24 F30 or the modified special tool 2 359 088 carefully in the corresponding mount until the snap-in hooks engage audibly.

Ensure that torsion spring (2) lies correctly in the lateral guides (arrows) and mark of clamping lever (1) when tensioning.

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Version with a torsion spring with an L-shaped contour with special tool 5 A24 F30 or the modified special tool 2 359 088 :
Close clamping lever (1) of special tool 5 A24 F30 or the modified special tool 2 359 088 carefully in the corresponding mount until the snap-in hooks engage audibly.
Ensure that torsion spring (2) lies correctly in the lateral guides (arrows) and mark of clamping lever (1) when tensioning.