11 31 001 Replacing camshaft (M52TU / M54 / M56): Installation

WARNING: This page is about a different car, the 2003 BMW 525i, 2002 BMW 525i, and 2001 BMW 525i. However, it is still accessible from the selected car via links, so may be relevant.

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

NOTE: Camshafts, bearings and bearing caps, friction washers, all splines on toothed shafts and spline hubs must be oiled before installation.

IMPORTANT: The bucket tappets expand when not subjected to load by the camshaft and therefore require some time before they can be pushed back down. During a rapid assembly sequence, the "closed" valves may still be open and be in contact with the piston.

Comply with following waiting periods after installing camshaft and before cranking engine back to TDC position.

Room temperature (20 °C) 4 mins
10 °C... 20°C 11 mins
0°C... 10 °C 30 mins

Pull up timing chain and feed in exhaust camshaft.

Position timing chain on exhaust camshaft.

Fig 1: Positioning Timing Chain On Exhaust Camshaft

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Install camshafts so that cam tips on inlet and exhaust valves on 1st cylinder face one another.

Fig 2: Installing Camshafts So That Cam Tips On Inlet & Exhaust Valves On 1St Cylinder Face One Another

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Fit bearing cover.

NOTE: Bearing caps are marked from exhaust side:

A1... A7 for exhaust side

E1... E7 for inlet side

Fig 3: Identifying Bearing Caps Marked From Exhaust Side

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Fit special tool 11 3 260 to cylinder head and screw into spark plug threads in cylinders 1 and 4.

Fig 4: Fitting Special Tool 11 3 260 To Cylinder Head & Screwing Into Spark Plug Threads In Cylinders 1 & 4

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Turn the eccentric shaft to tension the bearing caps.

Tighten down bearing cover.

Tightening torque. Refer to ENGINE - TIGHTENING TORQUES .

Remove special tool 11 3 260.

Fig 5: Turning Eccentric Shaft To Tension Bearing Caps

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IMPORTANT: Do not damage the cylinder head.

If necessary, machine open-end wrench accordingly.

Align camshafts with open-end wrench.

Fig 6: Aligning Camshafts With Open-End Wrench

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Fit special tool 11 3 240 to camshafts on cylinder 6. Align camshafts so that special tool 11 3 240 rests without gaps on cylinder head.

Fig 7: Fitting Special Tool 11 3 240 To Camshafts On Cylinder 6

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Attach special tool 11 3 244 to special tool 11 3 240 and locate by way of spark plug thread.

Fig 8: Attaching Special Tool 11 3 244 To Special Tool 11 3 240 & Locate By Way Of Spark Plug Thread

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Lift timing chain and hold under tension.

Turn engine from 30° before TDC position in direction of rotation as far as TDC position.

Fig 9: Lifting Timing Chain & Hold Under Tension

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Secure crankshaft in firing TDC position with special tool 11 2 300.

IMPORTANT: Remove special tool 11 2 300 before starting engine.

Fig 10: Securing Crankshaft In Firing TDC Position With Special Tool 11 2 300

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Automatic transmissions only:

Illustration does not show automatic transmission.

IMPORTANT: On engines with automatic transmissions, there is shortly before the special tool bore (1) a large bore (2) which can be confused with the special tool bore.

Fig 11: Identifying Special Tool Bore & A Large Bore

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If special tool 11 2 300 is secured in the correct bore (1), the engine can no longer be cranked at the central bolt.

Position sensor gear on inlet camshaft.

Fig 12: Positioning Sensor Gear On Inlet Camshaft

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Fit thrust washer and tighten down with dowels.

Tightening torque. Refer to ENGINE - TIGHTENING TORQUES .

Fig 13: Fitting Thrust Washer & Tightening With Dowels

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Feed chain wheel onto timing chain so that arrow on chain wheel faces separating face of upper side of cylinder head.

Fig 14: Feeding Chain Wheel Onto Timing Chain

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Insert special tool 11 4 220 in cylinder head and bring adjustment screw into contact with tensioning rail, but do not pretension timing chain yet.

Check arrow on chain wheel to separating face of upper side of cylinder head, reposition chain wheel if necessary.

Fig 15: Inserting Special Tool 11 4 220 In Cylinder Head

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Insert and tighten down screw-in pin.

Tightening torque. Refer to ENGINE - TIGHTENING TORQUES .

Fig 16: Inserting & Tightening Down Screw-In Pin

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Install secondary chain tensioner.

Fig 17: Installing Secondary Chain Tensioner

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Fit toothed sleeve (6) and align to toothed shaft in camshaft so that tooth gaps are opposed.

Fig 18: Fitting Toothed Sleeve & Aligning To Toothed Shaft In Camshaft

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Secure toothed shaft (5).

Insert pin of toothed shaft (5) into tooth gaps of splines on camshaft and toothed sleeve (6).

Fig 19: Inserting Pin Of Toothed Shaft Into Tooth Gaps Of Splines On Camshaft & Toothed Sleeve

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Push in toothed shaft (5) until the longitudinal holes in the toothed sleeve (6) are positioned centrally with respect to the thread.

Fig 20: Pushing In Toothed Shaft Until Longitudinal Holes In Toothed Sleeve Are Positioned

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Place chain wheels in special tool 11 6 180, position tooth gap on inlet chain wheel as shown in illustration and feed on chain.

Fig 21: Placing Chain Wheels In Special Tool 11 6 180

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IMPORTANT: Do not alter position of chain wheels with respect to chain when removing from special tool 11 6 180.

Remove chain with sprocket wheels positioned from special tool 11 6 180 and so that tooth spaces oppose each other on inlet side.

Fig 22: Removing Chain With Sprocket Wheels Positioned From Special Tool

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Align chain with sprocket wheels so that tooth spaces are positioned exactly over each other on inlet side.

Fig 23: Aligning Chain With Sprocket Wheels

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Secure toothed shaft (4).

Insert pin of toothed shaft (4) into tooth gaps of splines on camshaft and chain wheel.

Fig 24: Identifying Secure Toothed Shaft

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Push in toothed shaft (4) until approx. 1 mm of splines can still be seen.

Fig 25: Pushing In Toothed Shaft

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Note installation direction of corrugated washer (7), "FRONT" lettering must be visible.

Install corrugated washer, tighten nuts by hand but do not tighten down fully yet.

Fig 26: Installing Corrugated Washer & Tightening Nuts

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Insert screws on exhaust side, initially tighten to approx. 5 Nm and then slacken off again half a turn.

Fig 27: Inserting Screws On Exhaust Side

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Fit thrust washer (3).

Fig 28: Fitting Thrust Washer

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Note installation direction of cup spring (2), "F" lettering must be visible.

NOTE: If "F" lettering is no longer visible on an engine that has been run:

Install cup spring (2) so that small locating diameter of spring (2) points to sensor gear.

Fit cup spring (2) in position.

Fig 29: Fitting Cup Spring In Position

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Position sensor gear (1) so that arrow on sensor gear faces separating face of upper side of cylinder head.

Install nuts and tighten by hand but do not tighten down fully yet.

Fig 30: Positioning Sensor Gear

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Withdraw toothed shaft (5) up to stop.

Fig 31: Withdrawing Toothed Shaft Up To Stop

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Press down secondary chain tensioner at top and remove special tool 11 3 292.

Fig 32: Pressing Secondary Chain Tensioner At Top & Removing Special Tool 11 3 292

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Preload tensioning rail with special tool 11 4 220 by rotating adjusting screw with special tool 00 9 250 or standard torque wrench to 0.7 Nm.

Fig 33: Preloading Tensioning Rail With Special Tool 11 4 220 By Rotating Adjusting Screw

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Preload cup spring slightly by pressing on sensor gear (1) and tighten nuts by hand.

IMPORTANT: Do not tighten down nuts fully.

Fig 34: Preloading Cup Spring Slightly By Pressing On Sensor Gear & Tightening Nuts By Hand

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Remove gasket.

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

Keep sealing face clean and free of oil.

Fig 35: Checking Dowel Sleeves For Damage & Correct Installation Position

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IMPORTANT: Fit special tool 11 6 150 "without gasket" only.

If gasket remains underneath special tool 11 6 150, camshaft timing will be "incorrectly" set.

Attach special tool 11 6 150 "without gasket", tighten nuts by hand and then tighten down uniformly until special tool 11 6 150 is in full contact with cylinder head.

Fig 36: Identifying Nuts Of Cylinder Head

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Insert screws (1) on exhaust side and initially tighten to approx. 5Nm.

Fig 37: Inserting Screws On Exhaust Side

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Initially tighten nuts (2) on exhaust side and nuts (3) on inlet side to approx. 5 Nm.

Fig 38: Identifying Nuts On Exhaust Side & Nuts

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Tighten down screws (1) on exhaust side.

Tightening torque. Refer to ENGINE - TIGHTENING TORQUES .

Fig 39: Tightening Screws On Exhaust Side

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Tighten down nuts (2) on exhaust side and nuts (3) on inlet side.

Tightening torque. Refer to ENGINE - TIGHTENING TORQUES .

Fig 40: Tightening Nuts On Exhaust Side & Inlet Side

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Pull special tool 11 2 300 back until flywheel is no longer secured in position.

Fig 41: Pulling Special Tool 11 2 300 Back Until Flywheel Is No Longer Secured In Position

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Remove special tool 11 3 244 and special tool 11 3 240.

Fig 42: Removing Special Tool 11 3 244 & Special Tool 11 3 240

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Crank engine twice in direction of rotation until cam tips on inlet and exhaust camshafts on 1st cylinder face one another.

Fig 43: Cranking Engine Twice In Direction Of Rotation

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Secure crankshaft in firing TDC position with special tool 11 2 300.

IMPORTANT: Do not turn the engine back.

Remove special tool 11 2 300 before switching on the engine.

Fig 44: Securing Crankshaft In Firing TDC Position With Special Tool 11 2 300

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Fit special tool 11 3 240 to camshafts.

Fig 45: Fitting Special Tool 11 3 240 To Camshafts

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NOTE: The timing is correctly set if the special tool 11 3 240 rests without a gap on the cylinder head or protrudes up to 1 mm to the inlet side.

The timing must be reset if the special tool 11 3 240 protrudes to the exhaust side.

Fig 46: Identifying Special Tool 11 3 240 Protrudes To Exhaust Side

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Remove special tool 11 6 150.

Install VANOS adjustment unit.

Assemble engine.

Fig 47: Removing Special Tool 11 6 150

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