11 12 106 Removing and installing right cylinder head (N62 to 9/03)

WARNING: This page is about a different car, the 2005 BMW 545i and 2004 BMW 545i. However, it is still accessible from the selected car via links, so may be relevant.

(Cylinder Bank 1 To 4)

NOTE: To remove the exhaust manifolds, the engine must be secured in the installation position with the special tool and then the front axle bracket lowered.

Remove right exhaust manifold.

After Removing Exhaust Manifolds:

Reinstall front axle bracket provisionally and remove special tool for securing engine in installation position.

Open drain plug for coolant on right side of engine block.

Drain off coolant and dispose of correctly.

Installation:

Replace sealing ring.

Tightening torque, refer to of drain plug 11 11 5AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Top up coolant.

Vent cooling system and check for leaks. Refer to 17 00 039 VENTING COOLING SYSTEM AND CHECKING FOR LEAKS (N62, N62TU) .

Remove ignition coils on cylinder bank 1 to 4.

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

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

Remove intake air manifold. Refer to 11 61 050 REMOVING AND INSTALLING INTAKE AIR MANIFOLD (N62) .

Remove right timing case cover. Refer to 11 14 085 REMOVING AND INSTALLING TOP RIGHT TIMING CASE COVER (N62 / N62TU) .

Unfasten plug connection.

Place engine wiring harness to one side.

Remove spark plugs on cylinder bank 1 to 4.

Remove vent hose on cylinder head.

NOTE: Illustration with engine removed.

Detach hose (1) on check valve (4). Release screws (2).

IMPORTANT: A spacer bushing is secured with screw (3) behind tube (5).

Release screw (3) and remove check valve (4), tube (5) and spacer bushing.

Unclip cables (6 and 7).

Installation:

Replace sealing ring on tube (5) and coat with antiseize agent.

Removal:

Removal of cylinder head is described separately from installation.

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) .

Fig 1: Identifying Components Of Right Cylinder Head (N62 To 9/03)

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Slacken off chain tensioning piston (1) by approx. one turn.

Fig 2: Locating Chain Tensioning Piston

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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 3: Securing Torsion Spring With A Cable Strap

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

Fig 4: Aligning Eccentric Shaft At Dihedral Head

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NOTE: Spring mount (1) has a locating pin opposite screw.

Release screw.

Feed spring mount (1) upwards out of locating pin.

Fig 5: Feeding Spring Mount Upwards Out Of Locating Pin

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NOTE: Illustration with engine removed.

Remove eccentric shaft sensor (2).

Fig 6: Removing Eccentric Shaft Sensor

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Detach guide rail from cylinder head.

Fig 7: Detaching Guide Rail From Cylinder Head

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Release screws between cylinder head and timing case cover.

Fig 8: Releasing Screws Between Cylinder Head And Timing Case Cover

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NOTE: At narrow points, use a socket with 3/8" drive and a short extension.

Slacken off cylinder head bolts by one turn in sequence 10-1.

Fig 9: Identifying Removal Sequence Of Cylinder Head Bolts

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Rotate eccentric shaft at dihedral head as shown in illustration and hold in this position.

Remove cylinder head bolt (7).

Fig 10: Removing Cylinder Head Bolt (7)

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

Remove remaining cylinder head bolts.

Lift off cylinder head.

Lift off cylinder head gasket.

Fig 11: Aligning Eccentric Shaft To Minimum Stroke Position

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Remove chain tensioning piston (1).

Fig 12: Removing Chain Tensioning Piston

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Place chain tensioning piston (1) on a level surface and compress slowly and carefully.

Repeat this procedure twice.

Installation:

Installation of cylinder head is described separately from removal.

Clean sealing faces of cylinder head and crankcase; if necessary, remove gasket debris with wooden scraper. Make sure no gasket debris drops into the oil and coolant ducts.

Threaded bores in engine block must be free of dirt and oil (risk of cracking).

Fig 13: Compressing Chain Tensioning Piston

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Replace sealing ring.

Install chain tensioning piston (1) and initially tighten screw connection without play.

Fig 14: Locating Chain Tensioning Piston

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Coat joint between engine block and timing case cover with Drei Bond 1209.

Fig 15: Coating Joint Between Engine Block And Timing Case Cover With Drei Bond 1209

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

Fit new cylinder-head seal.

Fig 16: Identifying Dowel Sleeves

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Put the cylinder head on.

NOTE: Cylinder head bolt (7) cannot be inserted yet.

Do not wash off bolt coating. Insert new cylinder head bolts and initially tighten so that they are free of play.

Fig 17: Right Cylinder Head Bolts Tightening/Loosening Sequence (N62)

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Rotate eccentric shaft at dihedral head as shown in illustration and hold in this position.

Insert cylinder head bolt (7).

Fig 18: Inserting Cylinder Head Bolt

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

Fig 19: Aligning Eccentric Shaft To Minimum Stroke Position

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NOTE: At narrow points, use a socket with 3/8" drive and a short extension.

Tighten down the cylinder-head bolts in order 1-10.

Tightening torque, refer to 11 12 8AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 20: Right Cylinder Head Bolts Tightening/Loosening Sequence (N62)

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Insert and tighten down screws between cylinder head and timing case cover.

Fig 21: Locating Screws Between Cylinder Head And Timing Case Cover

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Insert and tighten down guide rail screw.

Fig 22: View Of Guide Rail Screw

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Replacement:

Open plug (1).

Fig 23: Identifying Screw Plugs

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Grip at dihedron and release screw (1).

Convert lever (2) with roller.

IMPORTANT: Levers (2) with rollers of cylinders 1 to 4 and 5 to 8 are different and must not be mixed up.

Fig 24: View Of Lever With Roller

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NOTE: Spring mount (1) has a locating pin opposite screw.

Attach spring to spring mount (1).

Insert locating pin of spring mount (1) into locating bore in cylinder head.

Install screw and tighten down.

Fig 25: View Of Locating Pin Of Spring Mount

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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 26: Securing Torsion Spring With Cable Strap

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

Fig 27: Aligning Eccentric Shaft To Minimum Stroke Position

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NOTE: Illustration with engine removed.

Install eccentric shaft sensor (2).

Fig 28: Locating Eccentric Shaft Sensor Retaining Screws

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Tighten down chain tensioning piston (1).

Tightening torque, refer to 11 31 8AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 29: Identifying Chain Tensioning Piston

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

Assemble engine.