11 36 048 Removing and installing/replacing inlet and exhaust adjustment units on right side (N62/N62TU)

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.

NOTE:

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

Special Tools Required:

11 9 190
11 9 460
11 9 461
11 9 462
11 9 463

(Cylinder Bank 1 To 4)

Necessary Preliminary Tasks:

Read fault memory and make a documentary record.
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 all spark plugs on cylinder bank 1 to 4.
If necessary, remove fan cowl.
Remove right timing case cover. Refer to 11 14 085 REMOVING AND INSTALLING TOP RIGHT TIMING CASE COVER (N62 / N62TU) .

Removal:

Removal of inlet and exhaust adjustment units is described separately from installation.

CAUTION: Screw (1) is a special screw and must not be replaced with a normal M8 screw.

Release screw (1).

Unclip oil line (3) from retainers (2) and remove.

Fig 1: Locating Oil Line In Retainers

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Crank engine at central bolt in direction of rotation to firing TDC position of 1st cylinder.

NOTE: In firing TDC position, cam of exhaust camshaft at 1st cylinder points upwards at an angle.

Cam of inlet camshaft points downwards at an angle:

Fig 2: Identifying Cams Of Inlet And Exhaust Camshafts

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NOTE: Alignment hole for TDC position is at front on timing case cover.

Crank engine at central bolt and secure vibration damper with special tool 11 9 190 in firing TDC position of 1st cylinder.

Fig 3: Securing Vibration Damper With Plug Mandrel

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IMPORTANT: When the engine is shut down, the inlet and exhaust adjustment unit is normally locked in its initial position. The situation may arise in some individual cases where this initial position is not reached and the camshaft can continue to be rotated in the adjustment range of the adjustment unit. In order to avoid incorrect timing adjustment, it is essential to check the locking of the adjustment unit and if necessary perform locking by rotating the camshafts.

Checking locking of inlet adjustment unit in initial position:

Engage hexagon head of inlet camshaft and attempt to rotate inlet camshaft carefully against direction of rotation.

If there is no fixed connection between inlet camshaft and inlet adjustment unit, rotate inlet camshaft against direction of rotation as far as it will go.

The inlet adjustment unit is locked in the initial position when the inlet camshaft is non-positively connected to the inlet adjustment unit.

Fig 4: Checking Locking Of Inlet Adjustment Unit

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Checking locking of exhaust adjustment unit in initial position:

Engage hexagon head of exhaust camshaft and attempt to rotate exhaust camshaft carefully in direction of rotation.

If there is no fixed connection between exhaust camshaft and exhaust adjustment unit, rotate exhaust camshaft in direction of rotation as far as it will go.

The exhaust adjustment unit is locked in the initial position when the exhaust camshaft is non-positively connected to the exhaust adjustment unit.

Fig 5: Checking Locking Of Exhaust Adjustment Unit

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IMPORTANT: If the inlet or exhaust adjustment unit of the camshafts "cannot" be locked as described, the adjustment unit is faulty and must be replaced.

Remove special tool 11 9 190.

Crank engine at central bolt against direction of rotation to 45° before TDC position.

Fig 6: Identifying 45° Before TDC Position

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NOTE: When slackening screws, grip camshafts at hexagon head.

Slacken screws of exhaust and inlet adjustment unit.

Fig 7: Locating Screws Of Exhaust And Inlet Adjustment Unit

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Remove screw on inlet adjustment unit.

Fig 8: View Of Screw On Inlet Adjustment Unit

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Vigorously press back tensioner rail (3) several times to remove oil in chain tensioner.

Feed out inlet adjustment unit (1).

Fig 9: Identifying Inlet Adjustment Unit

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Remove screw on exhaust adjustment unit.

Fig 10: Locating Screw On Exhaust Adjustment Unit

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Feed out exhaust adjustment unit (2).

Secure timing chain against slipping down.

Fig 11: View Of Exhaust Adjustment Unit

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Installation:

Installation of inlet and exhaust adjustment units is described separately from removal.

IMPORTANT: Danger of mix-up:

The inlet and exhaust adjustment units are different.

Mixing up the inlet and exhaust adjustment units will cause damage to the engine.

Inlet adjustment unit (1) is marked with EIN and IN.
Exhaust adjustment unit (2) is marked with AUS and EX.

Fig 12: Identifying Inlet Adjustment Unit And Exhaust Adjustment Unit Markings
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NOTE: The exhaust adjustment unit on cylinder bank 1 to 4 also has a metal clip (3) for driving the vacuum pump.

Fig 13: Locating Metal Clip For Driving Vacuum Pump

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NOTE: Position of exhaust adjustment unit (2) to timing chain can be freely selected.

Pull timing chain up.

Feed exhaust adjustment unit (2) into timing chain and fit onto exhaust camshaft.

Fig 14: View Of Exhaust Adjustment Unit

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Replace screw.

Install screw on exhaust adjustment unit.

Tighten screw without play and then slacken off again by half a turn.

Fig 15: Locating Screw On Exhaust Adjustment Unit

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NOTE: Position of inlet adjustment unit (1) to timing chain can be freely selected.

Pull timing chain up.

Feed inlet adjustment unit (1) into timing chain.

Press tensioner rail (3) back and fit inlet adjustment unit (1) onto inlet camshaft.

NOTE: If tensioner rail (3) cannot be pressed back far enough to enable fitting of inlet adjustment unit (1): Slacken off chain tensioner by approx. three turns. Fit inlet adjustment unit (1). Replace and insert screw on inlet adjustment unit (1). Tighten down chain tensioner. Tightening torque of chain tensioner, refer to 11 31 8AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 16: Locating Inlet Adjustment Unit

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Tighten screw on inlet adjustment unit without play and then slacken off again by a half turn.

Fig 17: Identifying Screw On Inlet Adjustment Unit

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Get special tool kit 11 9 460 ready for securing camshafts.

NOTE: Special tool 11 9 461 for securing inlet camshaft. Special tool 11 9 462 for securing exhaust camshaft. Special tool 11 9 463 (holder with screw).

Fig 18: Identifying Special Tool Kit 11 9 460 For Securing Camshafts

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Place special tool 11 9 461 on inlet camshaft and align inlet camshaft so that special tool 11 9 461 rests without a gap on cylinder head.

Fig 19: View Of Gauge On Inlet Camshaft

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Fit special tool 11 9 463, secure screw (1) in thread for oil line and tighten down by hand.

Fig 20: Securing Screw In Thread For Oil Line

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IMPORTANT: Make sure screws of inlet and exhaust adjustment units have been slackened off.

Crank engine at central bolt from 45° before TDC position in direction of rotation to firing TDC position.

Secure vibration damper with special tool 11 9 190 in firing TDC position of 1st cylinder.

Fig 21: Securing Vibration Damper With Plug Mandrel

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: When tightening down screw (1), grip camshaft at hexagon head.

Tighten down screw (1) of inlet adjustment unit.

Tightening torque, refer to 11 36 16AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 22: Identifying Screw Of Inlet Adjustment Unit

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Release screw (1), remove special tools 11 9 463 and 11 9 461 from inlet camshaft.

Fig 23: View Of Inlet Camshaft And Gauge

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Place special tool 11 9 462 on exhaust camshaft and align exhaust camshaft so that special tool 11 9 462 rests without a gap on cylinder head.

Fig 24: Aligning Exhaust Camshaft To Gauge

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Fit special tool 11 9 463, secure screw (1) in thread for oil line and tighten down by hand.

Fig 25: Securing Screw In Thread For Oil Line

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NOTE: When tightening down screw (2), grip camshaft at hexagon head.

Tighten down screw (2) of exhaust adjustment unit.

Tightening torque, refer to 11 36 16AZ in ENGINE - TIGHTENING TORQUES - 545I (4.4L) E60 .

Fig 26: Locating Screw Of Exhaust Adjustment Unit

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Release screw (1), remove special tools 11 9 463 and 11 9 462 from exhaust camshaft.

Fig 27: View Of Gauge On Exhaust Camshaft

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Remove special tool 11 9 190.

Crank engine at central bolt twice in direction of rotation until engine returns to firing TDC position of 1st cylinder.

Secure vibration damper with special tool 11 9 190 in firing TDC position of 1st cylinder.

Fig 28: Securing Vibration Damper With Plug Mandrel

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Place special tool 11 9 461 on inlet camshaft and check timing.

NOTE: The timing is correctly adjusted when special tool 11 9 461 rests flat on the cylinder head or protrudes by up to 0.5 mm to the exhaust side.

Fig 29: View Of Gauge On Inlet Camshaft

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Place special tool 11 9 462 on exhaust camshaft and check timing.

NOTE: The timing is correctly adjusted when special tool 11 9 462 rests flat on the cylinder head or protrudes by up to 0.5 mm to the exhaust side.

Fig 30: Installing Special Tool 11 9 462 On Exhaust Camshaft

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Remove all special tools.

IMPORTANT: Screw (1) is a special screw and must not be replaced with a normal M8 screw.

Clip oil line (3) into retainers (2).

Insert screw (1) and tighten down.

Assemble engine.

Fig 31: View Of Oil Line In Retainers

Courtesy of BMW OF NORTH AMERICA, INC.