Cylinder Head Remove and Install

REMOVING CYLINDER HEAD
- Unscrew exhaust pipes on exhaust manifolds and pipe clamp on transmission.

Installation Note:
- Check gaskets, replacing if necessary.
- Coat studs with copper paste "CRC".
- Replace self-locking nuts. Torque as follows:
Triangular flange 22 ± 2 Nm (16 ± 1.5 ft lb).
Version with spring Torque nuts (1) uniformly to 10 Nm (7 ft.lbs.)to flatten springs (2) and then loosen nuts one and one half turns.





CAUTION: Disconnecting the battery will cancel (clear) the memory of control units which have diagnostic trouble code capabilities. Be sure to interrogate all control units for possible diagnostic trouble codes prior to disconnecting the battery.
BMW anti-theft radios can be rendered useless by disconnecting the battery. Make sure you know the correct code before disconnecting the battery. See your owner's manual for more information.

- Unscrew plug and drain coolant.
- Disconnect battery ground lead.

Installation Note:
- Fill cooling system with coolant and bleed.
- Replace engine oil.




- Disconnect accelerator cable (7), cruise control cable (8) and throttle cable (9).

Installation Note:
- Adjust accelerator cable.
- Adjust cruise control cable.
- Adjust throttle pressure cable.




- Remove cover (10) and cap (11).
- Pull off plug (12) and lift out relay,
- Disconnect wire harness (13).




- Pull off plug (1) and lift out wires.
- Pull off plug (2) and unscrew nut (3).
- Pull off hoses (4 ... 7).
- Open clips (8).
- Loosen hose clamp (9).
- Unscrew nuts (10) and remove air cleaner with air flow sensor.




- Pull off plug.
- Disconnect fuel return line (11) and coolant hose (12).




- Disconnect fuel feed lines and heater hoses (8 and 9).
- Disconnect water hose for expansion tank.
- Pull off vacuum hose.




- Remove bolt (13).
- Disconnect wires (14 and 15) on alternator and starter.
- Lift out end disconnect plugs (16).




- Unscrew ignition lead tube (10) and distributor cap.
- Unscrew diagnosis socket.
- Remove bolts (11).
- Disconnect DME plugs (13 and 17).
- Pull off hose (15).
- Take off cylinder head cover.

Installation Note: Check that gasket seats correctly.




Installation Note: Connect DME plugs for reference mark and speed signals in such a manner. that gray plug (17) is connected with the plug marked with a ring.




- Pull off plugs on fuel injectors (1 ... 6), cold start valve (7), idle positioner (8), oil pressure switch (9) and throttle (10).
- Unscrew clamp (11) and ground lead (12).
- Disconnect engine wire harness and place aside to the right.




- Remove upper timing case cover.
- Remove chain tensioner piston.
- Open lockplates.
- Unscrew sprocket.

Installation Note Lockplates are not used again. Tightening torque, Sprocket To Camshaft Flange 6mm 10 Nm (7 ft lb).





Installation Note: Install timing chain that dowel pin (1) is at bottom left when tapped bores are perpendicular to the engine.




- Unscrew cylinder head bolts in order of 14 through 1.
- Insert Special Tools 11 1 063 as shown in picture, to prevent moving or turning of rocker arm shafts.
- Lift off cylinder head.




INSTALLING CYLINDER HEAD:
- Replace cylinder head gasket, Cylinder Head Gasket, Replace.
- Mount cylinder head and tighten bolts (washed and lubricated with oil) in order of 1 through 14 in three steps.
Step 1: Tightening torque = 60 Nm (45 ft.lbs) Wait 20 minutes.
Tighten bolts 1 through 6 first, then remove Special Tools 11 1 063 and tighten bolts 7 through 14 afterwards.
Step 2: Tightening torque = 80 Nm (59 ft.lbs.) Run engine warm 25 minutes.
Step 3: Torque angle = 35 degrees

CAUTION: Keep oil out of cavities in engine block (danger of cracking block, falsified torque values).

- Reinstall all auxiliary components in reverse order of disassembly, paying close attention to installation notes and torque specs.
- Adjust valve clearance,Valve Clearance.
- Check ignition timing.
- Check engine idle speed and CO level.